Dodge - Journey Awd - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Dodge Model Journey Awd Engine and year V6-3.5L (2009) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way Entertainment System Control Module: Diagrams Satellite Video Module C2 (Body) 2 Way Connector C2 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 9 Entertainment System Control Module: Diagrams Satellite Video Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 10 Entertainment System Control Module: Diagrams Satellite Video Module C1 (Body) 16 Way Connector C1 - (BODY) 16 WAY MODULE-SATELLITE VIDEO - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 11 Entertainment System Control Module: Diagrams Satellite Video Module C4 (Body) 2 Way Connector C4 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal Entertainment System Control Module: Service and Repair Satellite Video Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Move the front passenger seat to the most forward position. 3. Disconnect the three antenna connectors (1) and the electrical connector (2). 4. Remove the three retainers (1) securing the video module housing (2) to the floor, remove video housing and module from vehicle. 5. Remove the video module retainers (1) to the video module housing (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal > Page 14 Entertainment System Control Module: Service and Repair Satellite Video Module - Installation INSTALLATION 1. Install the video module to the housing. 2. Install the video module into the vehicle and Install the three retainers (1) securing the video module housing (2) to the floor.Tighten to 6 Nm (53 in. lbs.). 3. Connect the three antenna connectors (1) and the electrical connector (2). 4. Move the front passenger seat back to the original position. 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 18 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 19 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Hands Free Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Hands Free Module > Page 24 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams > Hands Free Module C1 (Instrument Panel) 22 Way Voice Activation Module: Diagrams Hands Free Module C1 (Instrument Panel) 22 Way Connector C1 - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams > Hands Free Module C1 (Instrument Panel) 22 Way > Page 27 Voice Activation Module: Diagrams Hands Free Module C2 (UCI) (Instrument Panel) 10 Way Connector C2 (UCI) - (INSTRUMENT PANEL) 10 WAY MODULE-HANDS FREE (UCI) - (INSTRUMENT PANEL) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Driver Door Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Driver Door Module > Page 33 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way Door Module: Diagrams Driver Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 36 Door Module: Diagrams Driver Door Module C3 (Express) (Front Door) 5 Way Connector C3 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 37 Door Module: Diagrams Driver Door Module C4 (Express) (Front Door) 5 Way Connector C4 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 38 Door Module: Diagrams Driver Door Module C5 (Express) (Front Door) 10 Way Connector C5 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 39 Door Module: Diagrams Driver Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Driver Door Module C3 (Express) (Front Door) 5 Way Connector C3 (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 40 MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Driver Door Module C4 (Express) (Front Door) 5 Way Connector C4 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 41 Driver Door Module C5 (Express) (Front Door) 10 Way Connector C5 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Passenger Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 42 MODULE-DOOR-PASSENGER (EXPRESS) - (FRONT DOOR) 10 WAY Passenger Door Module C3 (Except Base) (Front Door) 5 Way Connector C3 (EXCEPT BASE) - (FRONT DOOR) 5 WAY MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 43 Passenger Door Module C4 (Except Base) (Front Door) 5 Way Connector C4 (EXCEPT BASE) - (FRONT DOOR) 5 WAY MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 5 WAY Passenger Door Module C5 (Except Base) (Front Door) 10 Way Connector C5 (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 44 MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Door Module - Removal Door Module: Service and Repair Door Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel as necessary to gain access to the door control module. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the electrical connectors. 4. Remove the door control module mounting fasteners and remove the module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Door Module - Removal > Page 47 Door Module: Service and Repair Door Module - Installation INSTALLATION 1. Place the door control module into position and install the mounting fasteners. 2. Connect the electrical connectors. 3. Install the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Install the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 51 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 52 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 56 Seat Heater Control Module: Diagrams Connector - (SEAT) 10 WAY MODULE-HEATED SEATS - (SEAT) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located under the driver front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan (4). The module can be accessed from under the Driver seat with the seat in the full back and up position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 59 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate Diagnostic Trouble Code (DTC). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 60 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the driver front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 63 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 68 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 69 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 70 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Trailer Towing Relay: Diagrams Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 73 Trailer Towing Relay: Diagrams Right Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 74 Trailer Towing Relay: Diagrams Left Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 75 Trailer Towing Relay: Diagrams Right Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional trailer tow preparation package have four trailer tow relays, one each for the trailer tow stop/turn right and left and one each for the trailer stop lamp right and left. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are included with the trailer tow preparation wire harness that is shipped loose in the glove box for customer or dealer installation at the rear of the vehicle. A trailer tow stop/turn relay is located behind the rear fascia below each outer tail lamp, while a trailer stop lamp relay is located behind the rear fascia below each outboard end of the rear bumper reinforcement. Each relay and connector is wrapped within an isolator envelope for sound deadening and anti-rattle protection. Refer to the appropriate wiring information for specific relay cavity assignment information. Any of the trailer tow relays cannot be adjusted or repaired and, if ineffective or damaged, the affected unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 78 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Totally Integrated Power Module (TIPM) to the tail lamps to control a high current output to the trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right trailer tow stop/turn signal pins of the 4-way trailer tow connector at all times. The common feed terminals of both the left and right trailer tow stop relays is connected to the normally closed (87A) terminal of their respective left or right trailer tow stop/turn relay at all times. - Coil Ground Terminal (85) - The coil ground terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. The coil ground terminals of both the left and right trailer tow stop relays are connected to the stop lamp control circuit from the TIPM at all times. - Coil Battery Terminal (86) - The coil battery terminal of both the left and right trailer tow stop/turn relays is connected to a path to ground at all times. The coil battery terminal of both the left and right trailer tow stop relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. - Normally Open Terminal (87) - The normally open terminal of both the left and right trailer tow stop/turn relays is connected to the stop lamp control circuit from the TIPM whenever that relay is energized. The normally open terminal of both the left and right trailer tow stop relays is connected to a path to ground whenever that relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal of both the left and right trailer tow stop/turn relays is connected are connected to the common supply (30) terminal of their respective left or right trailer tow stop relay whenever the relay is de-energized. The normally closed terminal of both the left and right trailer tow stop relays is not connected to any circuit in this application. The trailer tow relays and the hard wired circuits for the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that provide some features of the trailer tow turn and stop lamp lighting system. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to trailer tow turn and stop lamp lighting operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal Trailer Towing Relay: Service and Repair Trailer Tow Relay - Removal REMOVAL TRAILER TOW STOP/TURN RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal 3. Disengage the left or right trailer tow stop/turn relay and connector from the isolator envelope (3) secured to the trailer tow wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Pull the relay straight out from the wire harness connector. TRAILER TOW STOP LAMP RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal 3. Disengage the left or right trailer tow stop lamp relay and connector from the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Pull the relay straight out from the wire harness connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal > Page 81 Trailer Towing Relay: Service and Repair Trailer Tow Relay - Installation INSTALLATION TRAILER TOW STOP/TURN RELAYS 1. Align the terminals of the left or right trailer tow stop/turn relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (3) secured to the wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Reinstall the rear fascia onto the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. TRAILER TOW STOP LAMP RELAYS 1. Align the terminals of the left or right trailer tow stop lamp relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Reinstall the rear fascia onto the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 86 Electronic Brake Control Module: Diagrams Connector - (HEADLAMP AND DASH) 47 WAY MODULE-ANTI-LOCK BRAKES - (HEADLAMP AND DASH) 47 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 87 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. NOTE: The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. For information on the ICU, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Description and Operation/Integrated Control Unit (ICU) - Description - DESCRIPTION). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 90 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - Illuminate the ESP function lamp in the message center on the instrument panel when a traction control event occurs. - Illuminate the ESP function lamp when the amber ABS warning indicator lamp illuminates. The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the ESP function lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - ESP/BAS warning indicator lamp - Diagnostic communication ABM OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication - ESP/BAS warning indicator lamp - Diagnostic communication Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Removal LEFT-HAND DRIVE NOTE: The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA. 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the engine appearance cover. 3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 4. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 93 6. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 7. Remove the wheelhouse brace (2). 8. Remove two screws, then remove the fresh air plenum. 9. Raise and support the vehicle. See: Maintenance 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) upward to near the top of the slots in the bracket, then snug one or both of the mounting screws (2) to hold the ICU in this position. 12. Lower the vehicle. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 13. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar(R) Brake Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 94 NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 14. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). 15. Remove the four screws (1) attaching the ABM (2) to the HCU. A Torx T20 bit approximately 2 inches long works well. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 95 CAUTION: When removing the ABM from the HCU, be sure to completely separate the two components (approximately 38 mm (1.5 inches)) before removing the ABM. Otherwise, damage to the pressure sensor or pump motor connection may result, requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 16. Separate the ABM (1) from the HCU (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 96 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Installation LEFT-HAND DRIVE 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 97 4. Align components and install the ABM (1) on the HCU (2). 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 98 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 6. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 7. Raise and support the vehicle. See: Maintenance 8. Loosen the two mounting screws (2) as necessary and allow the ICU (1) mounting bracket to slide down over the mounting screws and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). 9. Lower the vehicle. 10. Position the fresh air plenum and install the two mounting screws. 11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 99 12. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 13. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 14. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 15. Install the engine appearance cover. 16. Connect the negative cable on the battery negative post. 17. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 104 Radiator Cooling Fan Control Module: Diagrams Connector - (FRONT END MODULE) 2 WAY FAN MODULE-RADIATOR COOLING - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Radiator Fan High Speed Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Radiator Fan High Speed Relay > Page 109 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan Control Relay (In TIPM) 5 Way Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan Control Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RADIATOR FAN CONTROL - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan Control Relay (In TIPM) 5 Way > Page 112 Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan High Speed Relay (Front End Module) 5 Way Connector - (FRONT END MODULE) 5 WAY RELAY-RADIATOR FAN HIGH - (FRONT END MODULE) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 > Page 118 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 > Page 119 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 123 Blower Motor Relay: Diagrams Connector (3 ZONE HVAC) - (IN TIPM) 5 WAY RELAY-REAR BLOWER MOTOR (3 ZONE HVAC) - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF Control Module HVAC: Customer Interest A/C - Airflow From Vents With A/C OFF NUMBER: 24-008-08 GROUP: Air Conditioning DATE: September 4, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.01 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Airflow Through HVAC Ducts with System Off OVERVIEW: This Bulletin involves reprogramming the Three Zone Manual Temperature Control module with new software. MODELS: 2008 (RT) Grand Caravan/Town & Country 2009 (JC) Journey NOTE: This bulletin applies to RT equipped with 3 zone manual A/C (Sales Code HAG) built prior to April 16, 2008 (MDH0416XX) at Windsor Assembly plant (R in 11th VIN position) -OR- April 22, 2008 (MDH0422XX) at the St. Louis Assembly plant (B in 11th VIN position) NOTE: This bulletin applies to JC equipped with 3 zone manual A/C (Sales Code HAG) built before June 15, 2008 (MDH0615XX). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is noticeable while driving with the HVAC system off. This may be more noticeable with the temperature settings at medium or higher heat settings due to the temperature differential coming out of the ducts. Turning the blower on, and then off will force the fresh air/recirculation door closed eliminating the airflow. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C Systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 9.01 level software or higher. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 132 software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home" screen: a.Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 133 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF Control Module HVAC: All Technical Service Bulletins A/C - Airflow From Vents With A/C OFF NUMBER: 24-008-08 GROUP: Air Conditioning DATE: September 4, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.01 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Airflow Through HVAC Ducts with System Off OVERVIEW: This Bulletin involves reprogramming the Three Zone Manual Temperature Control module with new software. MODELS: 2008 (RT) Grand Caravan/Town & Country 2009 (JC) Journey NOTE: This bulletin applies to RT equipped with 3 zone manual A/C (Sales Code HAG) built prior to April 16, 2008 (MDH0416XX) at Windsor Assembly plant (R in 11th VIN position) -OR- April 22, 2008 (MDH0422XX) at the St. Louis Assembly plant (B in 11th VIN position) NOTE: This bulletin applies to JC equipped with 3 zone manual A/C (Sales Code HAG) built before June 15, 2008 (MDH0615XX). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is noticeable while driving with the HVAC system off. This may be more noticeable with the temperature settings at medium or higher heat settings due to the temperature differential coming out of the ducts. Turning the blower on, and then off will force the fresh air/recirculation door closed eliminating the airflow. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C Systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 9.01 level software or higher. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 139 software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home" screen: a.Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 140 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 146 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 147 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 153 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 154 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 155 Control Module HVAC: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 156 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way Control Module HVAC: Diagrams Front Blower Module (ATC) (Instrument Panel) 4 Way Connector (ATC) - (INSTRUMENT PANEL) 4 WAY MODULE-BLOWER-FRONT (ATC) - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way > Page 159 Control Module HVAC: Diagrams Rear Blower Module C1 (3 Zone ATC) (Body) 6 Way Connector C1 (3 ZONE ATC) - (BODY) 6 WAY MODULE-BLOWER-REAR (3 ZONE ATC) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way > Page 160 Control Module HVAC: Diagrams Rear Blower Module C2 (3 Zone ATC) (Body) 2 Way Connector C2 (3 ZONE ATC) - (BODY) 2 WAY MODULE-BLOWER-REAR (3 ZONE ATC) - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description Control Module HVAC: Description and Operation Front Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module . The blower motor power module is mounted to the bottom of the HVAC housing, on the passenger side of the vehicle. The blower motor power module consists of a molded plastic mounting plate (1) with an integral connector receptacle (2). Concealed behind the mounting plate is the power module electronic circuitry (3) and a finned aluminum heat sink (4). The blower motor power module is accessed for service from under the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 163 Control Module HVAC: Description and Operation Front Blower Motor Power Module - Operation OPERATION The blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the instrument panel wire harness. A second lead and connector of the instrument panel wire harness is connected to the blower motor. The blower motor power module allows the microprocessor-based automatic temperature control(ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 164 Control Module HVAC: Description and Operation Rear Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) rear heating-A/C system. Models equipped with the manual temperature control (MTC) rear heating-A/C system use a blower motor resistor, instead of the blower motor power module . The rear blower motor power module (1) is mounted to the inboard side of the rear heating-A/C housing, located on the right side of the vehicle. The rear blower motor power module consists of a molded plastic housing with two integral wire connector receptacles (2) for the power module electronic circuitry, a mounting plate (3) with a gasket and a finned aluminum heat sink (4). The rear blower motor power module can be accessed for service without removing the rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 165 Control Module HVAC: Description and Operation Rear Blower Motor Power Module - Operation OPERATION The rear blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the rear body wire harness. A second lead and connector of the wire harness is connected to the rear blower motor. The rear blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the rear blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The rear blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal Control Module HVAC: Service and Repair Front Blower Motor Power Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heat sink for the blower motor power module may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor power module, wait five minutes to allow the heat sink to cool before performing diagnosis or service. Failure to take this precaution may result in possible serious injury. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the blower motor power module (2) located at the bottom of the HVAC housing (3) on the passenger side of the vehicle. 3. Remove the two screws (4) that secure the blower motor power module to the HVAC housing and remove the power module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 168 Control Module HVAC: Service and Repair Front Blower Motor Power Module - Installation INSTALLATION NOTE: LHD model shown. 1. Position the blower motor power module (2) into the bottom of the HVAC housing (3). 2. Install the two screws (4) that secure the blower motor power module to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor power module. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 169 Control Module HVAC: Service and Repair Rear Blower Motor Power Module - Installation INSTALLATION 1. Position the rear blower motor power module (3) onto the rear heater-A/C housing (2). 2. Install the two screws (1) that secure the rear blower motor power module to the rear heater-A/C housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the two wire harness connectors (4) to the rear blower motor power module. 4. Install the right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 170 Control Module HVAC: Service and Repair Rear Blower Motor Power Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the two wire harness connectors (4) from the rear blower motor power module (3). 4. Remove the two screws (1) that secure the rear blower motor power module to the rear heater-A/C housing (2) and remove the module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Page 175 Brake Lamp Relay: Diagrams Connector - (BODY) 5 WAY RELAY-BRAKE LAMP - (BODY) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 181 Power Distribution Module: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 182 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 183 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 186 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 187 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 188 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 189 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 190 Power Distribution Module: Diagrams Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 191 Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 192 MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 193 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 194 Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 195 Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 196 Module-Totally Integrated Power C1 Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 197 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 198 Module-Totally Integrated Power C2 Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 199 Module-Totally Integrated Power C3 Connector C3 - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 200 MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Module-Totally Integrated Power C4 Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 201 Module-Totally Integrated Power C5 Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 202 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 203 Module-Totally Integrated Power C6 Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 204 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 205 Module-Totally Integrated Power C7 Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 206 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 207 Totally Integrated Power Module C2 (Headlamp And Dash) 26 Way Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 208 Totally Integrated Power Module C8 (Battery) 1 Way Connector C8 - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 209 MODULE-TOTALLY INTEGRATED POWER - (BATTERY) 1 WAY Totally Integrated Power Module C5 (Headlamp And Dash) 40 Way Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 210 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 211 Totally Integrated Power Module C6 (Headlamp And Dash) 40 Way Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 212 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 213 Totally Integrated Power Module C7 (Headlamp And Dash) 50 Way Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 214 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 215 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) Description Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located on the right side of the engine compartment. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the TIPM mounting bracket by four clips integral to the TIPM housing. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) Description > Page 218 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud with a nut. Internal connection of all the TIPM circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fuses, relays and TIPM housing assembly are available for service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 221 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Position the front drivers seat to the full rearward position. 3. Remove the power inverter (2) mounting retainers (1) located under the carpet. 4. Disconnect the electrical connectors. 5. Remove the power inverter module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 224 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Position the inverter into the vehicle and install mounting fasteners. 2. Connect the electrical connectors. 3. Connect the battery negative cable. 4. Position the front drivers seat back to the original position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 225 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Release the Totally Integrated Power Module (TIPM) cover retaining clips and open the TIPM cover. 4. Remove the TIPM positive cable retaining nut and remove the cable from the stud. 5. Depress the four mounting clips to disengage and remove the TIPM housing from its mounting bracket. 6. Disconnect each of the seven TIPM wire harness connectors. 7. Remove the TIPM from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 226 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from Dealer CONNECT 1. Position the TIPM into the engine compartment. 2. Connect each of the seven TIPM wire harness connectors. 3. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully seated. 4. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Tighten the nut to 9 - 11 Nm (80 - 100 in. lbs.). 5. Open the TIPM cover and fully seat the airbag fuse holder (two fuses in one yellow carrier) and the Ignition Off Draw (IOD) fuse. 6. Connect the battery negative cable. 7. Close the hood. 8. Insert the ignition key and turn it to the RUN position and wait twelve seconds. The TIPM will collect the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the OFF position and then back to the ON position and verify proper vehicle systems operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 231 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 232 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way Relay Box: Diagrams Run Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 235 Relay Box: Diagrams Run/Accessory Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/ACCESSORY - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 236 Relay Box: Diagrams Run/Start Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/START - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 237 Relay Box: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 238 Relay Box: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 249 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 250 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 251 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 252 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 253 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 254 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 255 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 256 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 257 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 258 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 259 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: Customer Interest Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 269 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 274 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: Customer Interest Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 279 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 284 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: Customer Interest Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 289 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 295 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 300 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 305 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 310 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 315 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 316 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 317 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 318 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 319 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 320 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 321 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 322 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 323 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 324 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 325 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 334 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 340 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 345 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 350 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 355 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 360 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 366 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 367 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 368 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 369 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 370 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 371 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 372 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 373 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 374 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 375 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 376 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 383 Engine Control Module: Locations Powertrain Control Module (NGC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 384 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Connector C1 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 387 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 388 Engine Control Module: Diagrams Powertrain Control Module C2 (NGC) (Engine) 38 Way Connector C2 (NGC) - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (ENGINE) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 389 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 390 Engine Control Module: Diagrams Powertrain Control Module C3 (NGC) (Headlamp And Dash) 38 Way Connector C3 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 391 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 392 Engine Control Module: Diagrams Powertrain Control Module C4 (NGC) (Transmission) 38 Way Connector C4 (NGC) - (TRANSMISSION) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (TRANSMISSION) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 393 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - ASD/Main Relay - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback (if equipped) - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Inlet Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral (from trans range sensor) - Power Steering Pressure Switch - Proportional Purge Sense - CAN C Bus - Speed Control - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Data Link Connector (CAN C Bus) - Double Start Override - EGR Solenoid (if equipped) - Fuel Injectors - Generator Field - High Speed Fan Relay - Ignition Coils - Natural Vacuum Leak Detection - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - 5 Volt Output Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation and EGR if equipped. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 396 rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Manifold Absolute Pressure - Engine Speed (crankshaft position sensor) - Battery Voltage - Inlet Air Temperature Sensor - Engine Coolant Temperature - Exhaust Gas Oxygen Content (heated oxygen sensors) - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed (from Transmission Control Module) The PCM adjusts ignition timing based on the following inputs. - Inlet Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral (from trans range sensor) - Transaxle Gear Engagement - Throttle Position The camshaft and crankshaft signals are sent to the Powertrain Control Module (PCM). If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the fuel pump. When deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. The PCM contains a voltage converter that changes battery voltage to a regulated 5.0 volts. The 5.0 volts power the camshaft position sensor, and crankshaft position sensor. The PCM also provides a regulated 5.0 volts supply for the, manifold absolute pressure sensor, throttle position sensor and EGR (if equipped). The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the scan tool to change the mileage in the PCM. Refer to the appropriate Powertrain Diagnostic Manual and the scan tool. If equipped with SKREEM, must use SKREEM function to program VIN number in new PCM. TRANSMISSION CONTROL CVI CALCULATION An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 397 Gear ratios can be determined by using the scan tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES The PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 398 Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Replacement PCM REPLACEMENT DESCRIPTION Use the scan tool to reprogram the new pcm with the vehicle's original identification number (vin) and the vehicle's original mileage. If this step is not done a Diagnostic Trouble Code (DTC) may be set. PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side of relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded via the mounting screws AND bracket to the chassis, separately from the ground pins. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 399 Engine Control Module: Description and Operation Powertrain Control Module - Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pullup resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 400 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 401 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. CHECKING THE PCM FUSED B+ CIRCUITS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 402 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Using a 12 volt test light connected to ground, check the PCM power supply circuits. 2. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 4. No - Repair the PCM power supply circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 4. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM (F202) and (F1) Fused Ignition circuits. 3. Wiggle test each circuit during the test to check for an intermittent open or short in the circuit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 403 NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Go to 5. No - Repair the open or short in the Fused Ignition Switch circuits. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition Switch circuits. 3. Check each circuit with the ignition off, ignition on, engine not running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the PCM Fused Ignition Switch circuit(s) for as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. PCM/TCM Programming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 406 > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using wiTECH(TM) Diagnostic Application. Go To REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See SECTION 3 AUTHORIZED MODIFCATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 407 SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Aisin TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quick learn Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 408 If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 409 - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 410 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Quick learn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quick learn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFCATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 411 TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids', under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Module/Programming Order Replacement Guide MODULE/PROGRAMMING ORDER REPLACEMENT GUIDE Module Programming Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 412 MODULE PROGRAMMING The Wireless Ignition Node (WIN) controls the Vehicle Theft Security System (VTSS), Remote Keyless Entry (RKE). When a Powertrain Control Module (PCM) is in need of replacement, perform the following steps in order: NOTE: The PCM and the WIN should never be replaced at the same time. They should be replaced independently of each other. 1. If applicable, first replace the PCM with the original WIN still connected to the vehicle. 2. Using a scan tool program the new PCM. (This will ensure the transfer of the Secret Key data from the original WIN into the new PCM). 3. Replace the WIN, using the scan tool program the new WIN module. This will transfer the Secret Key data from the PCM into the new WIN. 4. With the scan tool reprogram the key FOBIK to the new WIN. 5. Ensure all the customer's keys have been programmed to the new module. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SECRET KEY TO THE WIN The secret key is an ID code that is unique to each WIN. This code is programmed and stored in the WIN, the PCM, and each ignition key transponder chip. When the PCM or WIN is replaced, it is necessary to program the Secret Key Code into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, WIN REPLACED, or TIPM REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE menu item as appropriate. NOTE: Programming the PCM or WIN is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour and then enter the correct PIN. Be certain that all accessories are turned OFF. Also, monitor the battery state and connect a battery charger if necessary. PCM/WIN PROGRAMMING When an PCM and the WIN are replaced at the same time, perform the following steps in order: 1. Program the new WIN. 2. Replace all ignition keys and program them to the new WIN. PROGRAMMING THE WIN CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. NOTE: Have a unique vehicle PIN readily available before running the routine CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 3. Select "ECU View." 4. Select "WIN". 5. Select "Miscellaneous Functions." 6. Select "WIN Replaced". 7. Enter the PIN when prompted. 8. Cycle ignition key after the successful routine completion. NOTE: If the PCM and the WIN are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new WIN. PROGRAMMING IGNITION KEYS TO THE WIN Each FOBIK has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the WIN, the module learns the transponder ID code and the transponder acquires the unique Secret Key ID code from the WIN. CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 413 4. Ignition key should be in RUN position. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "Program Ignition Keys or Key FOBs", Start 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned by the WIN. Once a key is learned by a WIN, that key has acquired the Secret Key for that WIN and cannot be transferred to any other WIN or vehicle. PROGRAMMING THE PCM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. 4. Ignition key should be in RUN position. CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "PCM Replaced". 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 414 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL - NGC CONTROLLER NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and the negative battery cable must be disconnected before unplugging the PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the 4 electrical connectors at the PCM. 3. Remove the 3 fasteners (1) holding the PCM to the bracket. Powertrain Control Module - Installation INSTALLATION - NGC CONTROLLER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 415 NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM to bracket with 3 fasteners (1). 2. Install and lock the 4 electrical connectors to the PCM. 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 4. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 420 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 421 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 424 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 430 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 431 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 434 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 439 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way Air Bag Control Module: Diagrams Occupant Restraint Controller (Instrument Panel) 12 Way C2-A Connector - (INSTRUMENT PANEL) 12 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY C2-B Connector - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 442 MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 443 Air Bag Control Module: Diagrams Occupant Restraint Controller (Body) 36 Way C1-A Connector - (BODY) 36 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 444 C1-B Connector - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 445 MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 446 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 447 Air Bag Control Module: Diagrams Occupant Restraint Controller Module (Instrument Panel) 12 Way C2-A Connector - (INSTRUMENT PANEL) 12 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY C2-B Connector - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 448 MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 449 Air Bag Control Module: Diagrams Occupant Restraint Controller Module (Body) 36 Way C1-A Connector - (BODY) 36 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 450 C1-B Connector - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 451 MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 452 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the base of the dash panel and just forward on the center instrument panel support in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, electronic impact sensors and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with five screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label (2) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has three integral mounting tabs and two integral locating pins. The molded plastic electrical connector (3), with two receptacles containing numerous terminal pins, exits the rearward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one from the body wire harness and one from the instrument panel wire harness. The impact sensors internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without side curtain airbags or seat (thorax) airbags, with or without third row seating as well as for those vehicles with domestic or export applications. These variations are necessary for both equipment needs and for compliance with certain regulatory requirements. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 455 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness that is secured by a ground screw to the body sheet metal. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Various impact sensors within the ORC are continuously monitored by the ORC logic. These internal sensors, along with several external impact sensor inputs allow the ORC to determine both the severity of an impact and to verify the necessity for deployment of any airbags. Two remote front impact sensors are located on the back of the front end module carrier to the right and left of the cooling module near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The ORC also monitors inputs from an internal rollover sensor and up to six additional remote side impact sensors located on the left and right front door module carriers, on the right and left lower C-pillars and, on vehicles equipped with optional third row seating, on the right and left quarter inner panels to control deployment of the side curtain airbag units and seat (thorax) airbags. The impact sensors within the ORC are electronic accelerometer sensors that provide an additional logic input to the ORC microprocessor. These sensors are used to verify the need for a SRS component deployment by also detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. On vehicles equipped with side curtain airbags or seat airbags, a separate impact sensor within the ORC provides confirmation to the ORC microprocessor of side impact forces. This separate sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners, the seat airbags and either side curtain airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the mini console from the top of the floor panel transmission tunnel (3). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Removal. 3. First disconnect the instrument panel wire harness connector (4), followed by the body wire harness connector (5) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm to the fully open position on each connector. 4. Remove the three screws (1) that secure the ORC to the ORC bracket that is welded onto the top of the floor panel transmission tunnel. 5. Lift the ORC far enough to disengage the locating pins and remove the ORC from the bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 458 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Carefully position the Occupant Restraint Controller (ORC) (2) to the ORC bracket that is welded onto the top of the floor panel transmission tunnel. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle and the locating pins on the bottom of the ORC will be engaged into the locating holes in the ORC bracket. 2. Install and tighten the three screws (1) that secure the ORC to the ORC bracket. Tighten the screws to 12.5 Nm (9 ft. lbs.). CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged. 3. First reconnect the body wire harness connector (5), followed by the instrument panel wire harness connector (4) to the ORC connector receptacles located on the rearward facing side of the module. Be certain that the latches on both connectors are each fully engaged. 4. Reinstall the mini console onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. NOTE: Service replacement ORC modules are shipped in a LOCKED OUT state and after installed will set a ORC UNLOCKED - ALL DEPLOYMENT DISABLED fault. Use a diagnostic scan tool to access the ORC module and go to the MISCELLANEOUS FUNCTIONS menu item to perform the MODULE INITIALIZATION procedure to erase the fault and initialize the new replacement ORC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 463 Starter Relay: Diagrams Connector - (IN TIPM) 5 WAY RELAY-STARTER - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 474 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 475 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 476 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 477 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 478 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 479 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 480 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 481 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 487 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 488 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 489 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 490 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 491 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 492 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 493 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 494 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 498 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 501 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C3 (Instrument Panel) 4 Way Connector C3 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 502 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 503 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C8 (Steering Wheel) 6 Way Connector C8 - (STEERING WHEEL) 6 WAY MODULE-STEERING CONTROL - (STEERING WHEEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (1), control knob and control sleeve that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions and electrical connections are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the SCM through a jumper wire harness (5) directly to the right (wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is integral to the back of the switch housing and connects the SCM to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function switch must be replaced. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 506 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 507 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM). The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch (with integral Steering Control Module) - Right Multi-Function Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 508 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Page 509 Steering Mounted Controls Communication Module: Testing and Inspection STEERING CONTROL MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the Steering Control Module (SCM) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or the electronic controls or communication between modules and other devices that provide some features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM)See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 512 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 513 7. Disconnect the right switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 514 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 515 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 516 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure Control Module: Service and Repair Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure > Page 523 Control Module: Service and Repair Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 528 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 531 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the all-wheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 532 provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction control. It only works on situations where front-to-rear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Remove the left front trim panel. 2. Remove the electrical connector. 3. Remove the mounting nuts. 4. Remove the ECC module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 535 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Install ECC module into mounting studs. 2. Install mounting nuts and tighten to 8 Nm (71 in. lbs.) torque. 3. Install the electrical connector. 4. Install the left front trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 540 Heated Glass Element Relay: Diagrams Connector - (IN TIPM) 5 WAY RELAY-REAR WINDOW DEFOGGER - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Description and Operation > Headlamp Washer Relay - Description Headlamp Washer Motor Relay: Description and Operation Headlamp Washer Relay - Description DESCRIPTION The headlamp washer relay (1) is a conventional International Standards Organization (ISO) skirted relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns (2), and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The headlamp washer relay is located in a dedicated connector on a take out of the Front End Module (FEM) wire harness, and is secured to the radiator closure panel to the left of the washer reservoir in front of the Totally Integrated Power Module (TIPM) in the engine compartment, near the battery. The headlamp washer relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Description and Operation > Headlamp Washer Relay - Description > Page 546 Headlamp Washer Motor Relay: Description and Operation Headlamp Washer Relay - Operation OPERATION The headlamp washer relay is an electromechanical switch that uses a low current input from the Totally Integrated Power Module (TIPM) to control a high current output to the headlamp washer pump/motor unit. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The headlamp washer relay terminals are connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The inputs and outputs of the headlamp washer relay include: - Common Feed Terminal - The common feed terminal (30) is connected to battery current on a fused B(+) circuit from a fuse in the Totally Integrated Power Module (TIPM) at all times. Coil Ground Terminal - The coil ground terminal (85) is connected to battery current on a fused run relay output circuit from a fuse in the TIPM at all times. This circuit is energized by the run relay only while the engine is running. - Coil Battery Terminal - The coil battery terminal (86) is connected to a low side driver output from the TIPM on a headlamp washer relay control circuit. The TIPM controls headlamp washer system operation through this relay connection. - Normally Open Terminal - The normally open terminal (87) is connected through a headlamp washer relay output circuit to the headlamp washer pump/motor unit at all times. When the relay is energized, the normally open terminal of the relay is connected to battery current from the fuse in the TIPM. - Normally Closed Terminal - The normally closed terminal (87A) is not connected to any circuit in this application, but will have battery current present whenever the headlamp washer relay coil is not energized. The headlamp washer relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or the communication between modules and other devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer relay or the electronic controls and communication related to headlamp washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 552 Hood Sensor/Switch (For Alarm): Diagrams Connector - (FRONT END MODULE) 2 WAY SWITCH-HOOD AJAR - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 555 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (3) from the switch connector receptacle. 4. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 558 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation SWITCH NOTE: Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit. 1. Position the hood ajar switch (1) above the hole in the mounting bracket (2). 2. Press the switch into the mounting hole until the integral switch latch tabs lock it into place. 3. Connect the harness connector (3) to the switch connector receptacle. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 562 Integrated Accessory Switch Assembly: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY SWITCH-BANK - (INSTRUMENT PANEL) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation > Instrument Cluster Switch Pod - Description Integrated Accessory Switch Assembly: Description and Operation Instrument Cluster Switch Pod Description DESCRIPTION The Accessory Switch Bank Module (ASBM) is located in the center stack area of the instrument panel just below the heater and air conditioner duct and above the radio. This switch is available in multiple configurations, which vary from a single momentary push button switch to as many as six momentary push button switches, depending upon the optional equipment in the vehicle. The pod may include the following switches: - Heated Seats (if equipped) (1) - Electronic Stability Program Off (2) - Hazard Warning (3) - Headlamp Leveling (export only) (4) - Electrical Inverter On/Off (domestic only) (5) The switch housing and the push buttons are constructed of molded plastic. Each push button has a smooth finish and is clearly identified with the appropriate text and International Control and Display Symbol icons. Several of the push buttons feature Light Emitting Diode (LED) units to give the vehicle operator an indication when the function of that switch is currently active. Four screws secure the switch to the back of the instrument panel center bezel through integral mounting tabs that are molded into each corner of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. Panel lamps dimmer controlled illumination lamps integral to the circuit board within the switch provide back lighting for visibility at night, but these lamps are not serviceable. The individual switches in the ASBM cannot be repaired and are not serviced individually. If any component within the switch pod is ineffective or damaged, the entire switch pod must be replaced. The Domestic version of the ASBM is as follows: - Heated Seat Switches (if equipped) - See: Sensors and Switches - Body and Frame/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - ESP Off - See: Brakes and Traction Control/Description and Operation. - Hazard Switch (all models) - See: Sensors and Switches - Lighting and Horns/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Electrical Inverter (domestic models). The Export version of the ASBM will vary from the domestic: - Heated Seat Switches (if equipped) - See: Sensors and Switches - Body and Frame/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - Hazard Switch (all models) - See: Sensors and Switches - Lighting and Horns/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Headlamp Leveling Switch (if equipped) - . Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. See: Service and Repair/Instrument Cluster Switch Pod - Removal. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation > Instrument Cluster Switch Pod - Description > Page 565 Integrated Accessory Switch Assembly: Description and Operation Instrument Cluster Switch Pod Operation OPERATION For information covering details of operation for the individual switches or indicator contained within the instrument panel switch pod, refer to the specific service information covering the system to which that switch or indicator belongs. - Heated Seat Switches (if equipped) - See: Sensors and Switches - Body and Frame/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - ESP On/Off (domestic models) - See: Brakes and Traction Control/Description and Operation. - Hazard Switch (all models) - See: Sensors and Switches - Lighting and Horns/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Electrical Inverter (domestic models) - Headlamp Leveling Switch (if equipped) - . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod Removal Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Disconnect the electrical connector from the switch by depressing the lock tab and pulling connector from the ASBM. 4. Remove the four screws (1) to the Accessory Switch Bank Module (ASBM). 5. Remove the ASBM from the instrument panel center bezel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod Removal > Page 568 Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Installation INSTALLATION 1. Position the accessory switch bank module (ASBM) in the center bezel and install the four screws (1). 2. Connect the electrical connector to the ASBM. Be sure the lock tab engages securely into the ASBM. 3. Install the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 573 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 574 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 575 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 578 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 579 Remote Switch: Diagrams Left Steering Wheel Switch (EVIC) (Steering Wheel) 4 Way Connector (EVIC) - (STEERING WHEEL) 4 WAY SWITCH-STEERING WHEEL-LEFT (EVIC) - (STEERING WHEEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 580 Remote Switch: Diagrams Right Steering Wheel Switch (EVIC) (Steering Wheel) 10 Way Connector (EVIC) - (STEERING WHEEL) 10 WAY SWITCH-STEERING WHEEL-RIGHT (EVIC) - (STEERING WHEEL) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 581 Remote Switch: Description and Operation DESCRIPTION Remote radio control switches are rocker-type switch units are mounted in the upper spoke covers of the rear (instrument panel side) steering wheel trim cover. The switch unit on the left side is the seek switch and has seek up, seek down, and preset station advance switch functions. The switch unit on the right side is the volume control switch and has volume up, volume down, and mode advance switch functions. The two remote radio switch units are each retained in a mounting hole located on opposite sides of the rear steering wheel trim cover by four integral snap features. A plastic bracket on the back of each switch unit provides additional support for the unit by extending towards the center of the steering wheel where it is clamped between the steering wheel armature and the steering wheel rear trim cover mounting boss by the trim cover mounting screw. The two remote radio switch units share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 582 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test table. If the remote radio switch resistances check OK, go to 3. If not OK, replace the faulty switch. REMOTE RADIO SWITCH TEST 3. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for 5 volts at the radio control circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, refer to the proper Body Diagnostic Procedures. If not OK, repair the circuit as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Disconnect the horn connector (3). 4. Remove retainers (1) and remove the horn button assembly (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 585 5. Remove the speed control switch (3) See: Sensors and Switches - Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Removal. 6. Disconnect the radio switches (1). 7. From the inside of the steering wheel rear trim cover, press firmly and evenly outward on the back of the switch to disengage the four snap features that secure the switch to the inside of the mounting hole. 8. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 586 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch snap features is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch (1). 4. Install the speed control switch (3) See: Sensors and Switches - Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 587 5. Install the horn button assembly (2) and install the three retainers (1). 6. Connect the horn connector (3). 7. Install the driver side airbag module to the steering wheel See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag Installation. 8. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal > Page 593 Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Installation INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Install door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 598 Hood Sensor/Switch (For Alarm): Diagrams Connector - (FRONT END MODULE) 2 WAY SWITCH-HOOD AJAR - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 601 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (3) from the switch connector receptacle. 4. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 604 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation SWITCH NOTE: Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit. 1. Position the hood ajar switch (1) above the hole in the mounting bracket (2). 2. Press the switch into the mounting hole until the integral switch latch tabs lock it into place. 3. Connect the harness connector (3) to the switch connector receptacle. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch > Page 609 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 612 Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C2 (Front Door) 10 Way Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 613 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Except Base) (Front Door) 10 Way Connector (EXCEPT BASE) - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 614 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Base) (Front Door) 8 Way Connector (BASE) - (FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (BASE) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 615 Power Door Lock Switch: Testing and Inspection DIAGNOSIS AND TESTING VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: - Touch other test light lead to battery feed B+ terminal. - If test light comes on, the wiring circuit between the battery and switch is functional. - If test light does not come on, check for a blown fuse. Refer to Wiring Diagrams for circuit information. DOOR LOCK SWITCH NOTE: Vehicles equipped with the auto-express feature for power windows, the local interface network (LIN) controls the lock, mirror and window features. Remove the non-express switch from its mounting location. Using an ohmmeter, refer to the DOOR LOCK SWITCH CONTINUITY table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. DOOR LOCK SWITCH CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 618 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Connect switch wire connector. 2. Install the switch by snapping into place. 3. Connect the battery negative remote cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 623 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Connect switch wire connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 627 Power Seat Switch: Diagrams Connector - (SEAT) 11 WAY SWITCH-SEAT-DRIVER - (SEAT) 11 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description Power Seat Switch: Description and Operation Power Seat Switch - Description DESCRIPTION The driver power seat can be adjusted in six different ways using the power seat switch. The power seat switch (2) is located on the lower outboard side of the seat cushion (1) on the seat cushion side shield (3). The power seat system incorporates a seat switch with a seat cushion control paddle. The individual components in the power seat switch assembly cannot be repaired. If the switch is damaged or inoperative, the entire power seat switch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description > Page 630 Power Seat Switch: Description and Operation Power Seat Switch - Operation OPERATION When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 631 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to POWER SEAT SWITCH CONTINUITY table. If not OK, replace the faulty power seat switch. If switch tests OK See: Body and Frame/Seats/Testing and Inspection. POWER SEAT SWITCH CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the outboard seat cushion side shield (3). 3. Disconnect the power seat switch electrical harness connector (4). 4. Using a small flat bladed tool, gently release the four mounting tabs (1) that secure the power seat switch (2) and separate switch from side shield (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 634 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch (2) onto the seat cushion side shield (3). Gently apply pressure to the switch until the four mounting tabs (1) are fully seated into place. 2. Connect the power seat switch electrical connector (4). 3. Install the seat cushion outboard side shield. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description DESCRIPTION Two heated seat switches are located in the center stack of the instrument panel. The switches are located on the outer edges of the Accessory Switch Bank Module (ASBM). The ASBM (3) is located just below the radio (1) and just above the heater and air conditioner controls (2) in the center stack area of the instrument panel. If either of the switches is damaged or inoperative the complete ASBM assembly must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 639 Each heated seat switch (4) provides a resistor-multiplexed signal to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). Amber Light Emitting Diodes (LEDs) on the outside edge of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete ASBM assembly must be replaced, See: Service and Repair/Heated Seat Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 640 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation OPERATION The heated seat switches (4) are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 641 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The heated seat switches are integral to the Accessory Switch Bank Module (ASBM) and cannot be serviced separately. The complete ASBM assembly must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the four screws (1) that secure the ASBM (2) to the back of the instrument panel center bezel (3) and remove the ASBM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 644 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION NOTE: There are different Accessory Switch Bank Module (ASBM) configurations available based on the option content of the vehicle. Ensure the ASBM being installed matches the vehicle options. 1. Position the ASBM (2) onto the back of the instrument panel center bezel (3). 2. Install the four screws (1) that secure the ASBM to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 648 Sunroof / Moonroof Switch: Diagrams Connector - (HEADLINER) 4 WAY SWITCH-SUNROOF - (HEADLINER) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced, See: Service and Repair/Sunroof Switch Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description > Page 651 Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 652 Sunroof / Moonroof Switch: Testing and Inspection SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the overhead console assembly, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. POWER SUNROOF SWITCH CONTINUITY TABLE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using a suitable flat bladed tool, release the mounting tabs from the sides of the sunroof control switch and pull the switch out of the overhead console assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal > Page 655 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Installation INSTALLATION 1. Insert the sunroof control switch into the overhead console assembly. Push the switch until it is securely held in place by the mounting tabs. 2. Install the overhead console, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 660 Brake Fluid Level Sensor/Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-BRAKE FLUID LEVEL - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 661 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Removal REMOVAL NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) that hold the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal > Page 664 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 668 Lateral Accelerometer: Diagrams Connector - (BODY) 4 WAY SENSOR-DYNAMICS - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 669 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the lower instrument panel trim on each side of console below instrument panel. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 672 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 6. Perform the Verification Test and clear any faults. See: Brakes and Traction Control/Brake Bleeding/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 676 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 677 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a foot-operated or hand-operated park brake lever mechanism. FOOT-OPERATED Foot-Operated Park Brake Switch The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED Hand-Operated Park Brake Switch The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 680 connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 681 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 682 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 685 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 686 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 687 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION MODULE-ASBM The ESP Off Switch (2) is part of the accessory switch bank module located in the center bezel (2) on the instrument panel above the radio. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal > Page 693 Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test and make sure the ESP Off switch operates properly. See: Brakes and Traction Control/Brake Bleeding/Service and Repair 6. Verify proper operation of all components controlled by the switch bank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 698 Wheel Speed Sensor: Locations Left Rear Wheel Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 699 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 700 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way Wheel Speed Sensor: Diagrams Left Rear Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-LEFT REAR - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 703 Wheel Speed Sensor: Diagrams Right Rear Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-RIGHT REAR - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 704 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 705 Wheel Speed Sensor: Diagrams Right Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Description Front DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (2) is attached to a mounting boss on each front knuckle (3). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Rear DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. The rear wheel speed sensor (2) head is mounted to the rear hub and bearing (1). The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 708 WSS air gaps are not adjustable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 709 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Operation Front OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Rear OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. See: Maintenance 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 712 7. Remove the screw (2) securing the wheel speed sensor routing bracket (3) to the brake flex hose bracket (4). 8. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5). 9. Remove the mounting screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle and remove the sensor from the vehicle. Rear REMOVAL 1. Access and remove the rear brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 713 CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 2. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 3. Remove the wheel speed sensor routing clip (4) from the brake tube routing bracket (1). 4. Remove the wheel speed sensor cable from the routing clips (3) above the trailing arm. 5. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 714 6. Remove the screw (1) fastening the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3). 7. Remove the screw (2) securing the wheel speed sensor routing clamp (1) to the trailing link. 8. Disconnect the vehicle wiring harness (3) from the wheel speed sensor connector (2) on the body (1). 9. Disengage the wheel speed sensor connector from the routing clip fastened to the body using a screwdriver. Pull the connector forward off the routing clip. Or, if a NEW routing clip is available, remove the routing clip from the body with the connector attached. 10. Remove the wheel speed sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 715 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 3. Position the wheel speed sensor routing bracket (3) on the brake flex hose bracket (4) and install the mounting screw (2). Tighten the mounting screw to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 716 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 20 Nm (15 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Brakes and Traction Control/Brake Bleeding/Service and Repair Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 717 1. Slide the wheel speed sensor wiring connector (2) onto the routing clip mounted on the body until it locks into place or if a NEW routing clip is attached to the connector, push it into the mounting holes on the body. 2. Connect the vehicle wiring harness (3) to the wheel speed sensor connector (2). 3. Attach the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3) using the mounting screw (1). Tighten the mounting screw to 20 Nm (15 ft. lbs.). 4. Attach the wheel speed sensor routing clamp (1) to the trailing link using the mounting screw (2). Tighten the mounting screw to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 718 5. Apply bearing grease (supplied with part) to sensor head shaft and O-ring. CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 6. Pass the wheel speed sensor head through the hole in the brake shield, then push it into the mounting hole in hub and bearing (3) and align the mounting screw hole. 7. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). 8. Install the wheel speed sensor routing clip (4) in the brake tube routing bracket (1). 9. Install the wheel speed sensor cable into the routing clips (3) above the trailing arm. 10. Install brake rotor as well as all components necessary to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 11. Perform the ABS Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 722 Yaw Rate Sensor: Diagrams Connector - (BODY) 4 WAY SENSOR-DYNAMICS - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 723 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the lower instrument panel trim on each side of console below instrument panel. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 726 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 6. Perform the Verification Test and clear any faults. See: Brakes and Traction Control/Brake Bleeding/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 734 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 735 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 736 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 737 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 742 Cruise Control Switch: Diagrams Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL - (STEERING WHEEL) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 745 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. 2. Install speed control switch mounting screws (4) and tighten screws to 1.6 Nm (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3). 4. Install horn switch (2) to steering wheel. 5. Install horn switch mounting screws (3) and tighten screws to 8 Nm (71 ins. lbs.). 6. Connect electrical connector to horn switch. 7. Install driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag Installation. 8. Connect negative battery cable, tighten nut to 4.5 Nm (40 in. lbs.). 9. Verify vehicle and system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 750 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 751 Oil Pressure Sender: Diagrams Connector (GAS) - (ENGINE) 2 WAY SWITCH-OIL PRESSURE (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 756 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 762 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 767 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 772 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (FRONT END MODULE) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Description DESCRIPTION The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ATC system uses the sensor data to maintain optimum cabin temperature levels. The ambient air temperature sensor is mounted inside the front fascia. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description > Page 775 Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Operation OPERATION The ambient air temperature sensor is a variable resistor that operates on a 5-volt reference signal sent by the Totally Integrated Power Module (TIPM). The ambient air temperature sensor is connected to the TIPM through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes its internal resistance in response to changes in the outside air temperature, which either increases or decreases the reference signal voltage read by the TIPM. The TIPM converts and broadcasts the sensor data over the Controller Area Network (CAN) IHS bus, where it is read by the ATC A/C-heater control, Powertrain Control Module (PCM) and other vehicle control modules. The ambient air temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 779 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 780 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 781 Evaporator Temperature Sensor / Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SENSOR-EVAPORATOR TEMPERATURE - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description > Page 784 Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing See: Heating and Air Conditioning/Compressor HVAC/Description and Operation/A/C Compressor - Operation. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal > Page 787 Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 791 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (HEADLAMP AND DASH) 4 WAY TRANSDUCER-A/C PRESSURE - (HEADLAMP AND DASH) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C liquid line at the right front corner of the engine compartment. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting. A rubber O-ring seals the connection between the A/C pressure transducer and the A/C liquid line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description > Page 794 Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the Powertrain Control Module (PCM) or the Engine Control Module (ECM) (depending on engine application) over the CAN C BUS. With 3.5L 5-Passenger and all 7-Passenger models, the PCM is programmed to respond to this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. With 2.4L 5-Passenger models, A/C compressor clutch engagement is controlled by the PCM or ECM, depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-IHS bus to the TIPM, which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the TIPM to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C liquid line (3) at the right front corner of the engine compartment. 3. Remove the A/C pressure transducer from the A/C liquid line and remove and discard the O-ring seal (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal > Page 797 Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C liquid line (3). 2. Install the A/C pressure transducer (2) onto the A/C liquid line. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) > Page 802 Solar Sensor: Locations Sun Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) > Page 803 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (ATC) (Headliner) 4 Way Solar Sensor: Diagrams Infrared Sensor (ATC) (Headliner) 4 Way Connector (ATC) - (HEADLINER) 4 WAY SENSOR-INFRARED (ATC) - (HEADLINER) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (ATC) (Headliner) 4 Way > Page 806 Solar Sensor: Diagrams Sun Sensor (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-SUN - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description Solar Sensor: Description and Operation Infrared Temperature Sensor - Description DESCRIPTION The infrared temperature sensor is located in the overhead console and consists of an infrared transducer concealed behind a clear lens (2) in a molded plastic housing with an integral wire connector receptacle (1) and mounting tab (3). The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heating-A/C system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 809 Solar Sensor: Description and Operation Infrared Temperature Sensor - Operation OPERATION The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and surroundings and converts its data into a linear Pulse Width Modulated (PWM) output signal which is read by the Automatic Temperature Control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature levels. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store Diagnostic Trouble Codes (DTCs) for any problem it detects. The infrared sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 810 Solar Sensor: Description and Operation Sun Sensor - Description DESCRIPTION NOTE: Typical sun sensor assembly shown. The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 811 Solar Sensor: Description and Operation Sun Sensor - Operation OPERATION The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side variations in sun light intensity. Passengers in sun and shadow require different functional settings because they experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic headlight control, if equipped. The sun sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 812 Solar Sensor: Testing and Inspection SUN SENSOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in an accidental airbag deployment and possible serious or fatal injury. The sun sensor assembly is located so that the sun rays will hit the sensors in the same way that it will hit the driver and the passenger. It is important that the area in front of the sun sensor assembly be unobstructed. Check for the following: - Windshield wipers are properly adjusted. - Defroster grille or sun sensor is properly installed. The sun sensor lens should protrude above the defroster grille. - Any stickers on the windshield are not directly in front of the sun sensor. - Any items laying on top of the instrument panel are not covering the sun sensor. If the vehicle exhibits a lack of passenger comfort in sunny weather such as in the early afternoon, inspect the position of the sun sensor assembly. The sun sensor lens should protrude above the defroster grille to insure proper operation. If the sun sensor is not properly positioned, perform the following procedure: 1. Confirm that the defroster grille is properly installed. If not, repair as required. 2. Remove the defroster grille and verify that the sun sensor is properly installed to the instrument panel See: Service and Repair/Sun Sensor Installation. 3. Reinstall the defroster grille. The A/C-heater control continually monitors the sun sensor circuits and will store diagnostic trouble codes (DTCs) for any problem it detects. The sun sensor can be tested in the vehicle with a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal Solar Sensor: Service and Repair Infrared Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Using Trim Stick C-4755 or equivalent, carefully disengage the four retaining tabs (1) that secure the infrared sensor and overhead map/courtesy lamp bezel (2) to the overhead console (3). 3. Disconnect the wire harness connectors (4) from the two overhead map/courtesy lamps (5) and the infrared sensor (6) and remove the sensor, lamp and bezel assembly from the vehicle Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 815 Solar Sensor: Service and Repair Infrared Temperature Sensor - Installation INSTALLATION 1. Position the infrared sensor and overhead map/courtesy lamp bezel (2) to the overhead console (3). 2. Connect the wire harness connectors (4) to the two overhead map/courtesy lamps (5) and the infrared sensor (6). 3. Engage the four retaining tabs (1) that secure the infrared sensor and overhead map/courtesy lamp bezel to the overhead console. Make sure the retaining tabs are fully engaged. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 816 Solar Sensor: Service and Repair Sun Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 3. Using Trim Stick C-4755 or equivalent (2), gently pry between both sides of the sun sensor assembly (1) and the instrument panel (3) to release the snap retainers that secure the sun sensor. 4. Disconnect the wire harness connector (2) from the sun sensor assembly (1) and remove the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 817 Solar Sensor: Service and Repair Sun Sensor - Installation INSTALLATION 1. Position the sun sensor assembly (1) to the top of the instrument panel (4) and connect the wire harness connector (3). 2. Align the tab (2) on the sun sensor assembly with the opening in the instrument panel. 3. Gently push the sun sensor assembly into the instrument panel until the sensor snap retainers are securely engaged. 4. Install the defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 823 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 824 Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 825 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 828 Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 833 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 834 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 835 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 838 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 841 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 842 Fuel Gauge Sender: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 845 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 846 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 847 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 848 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 849 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 850 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 851 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 852 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 853 Fuel Gauge Sender: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Pump Module - Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 854 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 855 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Pump Module - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor (1) is a variable resistor located under the bottom right side of the front bumper reinforcement (2). The sensor is attached to the power steering line bracket with a pushpin style retainer and can be accessed through the right opening in the front fascia assembly. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description > Page 860 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The applicable instrument cluster display then displays the proper ambient temperature. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 861 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus, the Local Area Network (LIN) data bus and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (130° F), or if the sensor circuit is shorted, 60° C (130° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the instrument cluster may be necessary. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection/Component Tests and General Diagnostics for the appropriate procedure. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, further testing of the instrument cluster may be necessary. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection/Component Tests and General Diagnostics for the appropriate procedure. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the "ON" position for readings to meet test specifications. 1. Turn the ignition switch to the "OFF" position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the "ON" position. The display should now read - 40° C (- 40° F). If OK, go to 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the "OFF" position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the "ON" position. The display should now read 60° C (130° F). If OK, go to 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE: If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update. 5. Turn the ignition switch to the "OFF" position. Remove the jumper wire. Turn the ignition switch to the "ON" position and wait until the display again reads - 40° C (- 40° F). Turn the ignition switch to the "OFF" position. Reconnect the ambient temperature sensor. Turn the ignition switch to the "ON" position. The display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to 6 6. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the LIN data bus circuit, the TIPM and the ambient temperature sensor (refer to the SENSOR TEST). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Working through the opening in the right side of the front fascia, disconnect the wire harness connector from the ambient temperature sensor (1). 3. Remove the fastener that secures the ambient temperature sensor to the power steering line bracket. 4. Remove the ambient temperature sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal > Page 864 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Working through the opening in the right side of the front fascia, position the ambient temperature sensor (1) in the vehicle. 2. Install the fastener that secures the ambient temperature sensor (1) to the power steering line bracket. 3. Connect the wire harness connector to the ambient temperature sensor. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 868 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 869 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a foot-operated or hand-operated park brake lever mechanism. FOOT-OPERATED Foot-Operated Park Brake Switch The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED Hand-Operated Park Brake Switch The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 872 connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 873 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 874 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 877 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 878 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 879 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Backup Lamp Switch - Description Backup Lamp Switch: Description and Operation Backup Lamp Switch - Description DESCRIPTION Vehicles equipped with a manual transmission (2) have a normally open, spring-loaded plunger type backup lamp switch (1). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the left facing surface of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Refer to the service and diagnostic information for the manual transmission type installed in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Backup Lamp Switch - Description > Page 885 Backup Lamp Switch: Description and Operation Backup Lamp Switch - Operation OPERATION The backup lamp switch controls a path to ground for the Totally Integrated Power Module (TIPM) on the reverse switch signal circuit. The TIPM reads this input through an internal pull-up, then controls an output through a high side driver that regulates the flow of battery voltage to the backup lamp bulbs as appropriate on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives ground at all times through a take out and eyelet terminal of the wire harness that is secured to the body sheet metal. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the backup lamp switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to backup lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Page 886 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Locate and disconnect the engine wire harness connector from the backup lamp switch connector receptacle. 3. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 4. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch (Early Build) (Body) 6 Way Brake Light Switch: Diagrams Stop Lamp Switch (Early Build) (Body) 6 Way Connector (EARLY BUILD) - (BODY) 6 WAY SWITCH-STOP LAMP (EARLY BUILD) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch (Early Build) (Body) 6 Way > Page 892 Brake Light Switch: Diagrams Stop Lamp Switch (Normal Build) (Body) 6 Way Connector (NORMAL BUILD) - (BODY) 6 WAY SWITCH-STOP LAMP (NORMAL BUILD) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and both are illustrated and described in the paragraphs that follow. EARLY PRODUCTION This brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket on the dash panel under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. This brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. LATE PRODUCTION This brake lamp switch (1) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (4) containing six terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (2) on one end of the switch housing. The plunger has a telescoping self-adjustment feature that is activated after the switch is installed by pulling the brake pedal upward to its normal at-rest position. The telescoping plunger can be pulled outward from the switch housing to repeat the self-adjustment procedure if necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 895 This brake lamp switch cannot be repaired. If the switch is damaged or ineffective it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 896 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION Both the early and late production brake lamp switches control three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the Center High Mounted Stop Lamp (CHMSL) and the Totally Integrated Power Module (TIPM) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake signal 1 circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Totally Integrated Power Module (TIPM) on an ignition run/start control output circuit, and supplies this battery voltage to the PCM on a brake signal 2 circuit only when the brake pedal is released (brake lamp switch plunger is depressed). The PCM sends electronic brake lamp switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus for use as an additional logic input for controlling many other vehicle functions and features. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication that provide some features related to brake lamp switch operation. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to brake lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 897 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Early Production Late Production 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the Eary Production-type brake lamp switch from the mounting bracket. The self-adjusting plunger of this switch is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 898 Brake Light Switch: Adjustments ADJUSTMENT - LATE PRODUCTION TYPE ONLY Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and, only the late production type switch can be readjusted following initial installation using this adjustment procedure. If the early production type switch requires readjustment for any reason, it must be replaced with a new switch. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Depress and hold the brake pedal in the depressed position. 4. Pull the brake lamp switch plunger all the way out of the switch housing to its fully extended position. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 5. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 6. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch - Description. EARLY PRODUCTION 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Locate the brake lamp switch (3) on the brake pedal support bracket (2) under the instrument panel. 4. Disconnect the wire harness connector (4) from the switch. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket (1). 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Discard the removed brake lamp switch. The brake lamp switch self-adjusting plunger is a one time only feature. If the switch is removed from the bracket, it MUST be replaced with a new switch. LATE PRODUCTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 901 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Locate the brake lamp switch (2) on the brake pedal support bracket (4) under the instrument panel. 4. Depress and hold the brake pedal in the depressed position. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket. 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Release the brake pedal. 8. Disconnect the wire harness connector (1) from the switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 902 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch - Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. EARLY PRODUCTION CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Obtain a new brake lamp switch. The adjustment lever on the new switch should be at about a 45 degree angle to the switch connector receptacle. If the adjustment lever is parallel with the connector receptacle, the switch adjustment has already been set and the switch must be scrapped. DO NOT ATTEMPT TO RESET OR READJUST THE BRAKE LAMP SWITCH. 2. Depress and hold the brake pedal in the depressed position. 3. Align the tabs on the brake lamp switch (2) locking collar with the keyed hole in the brake pedal support bracket (1) below the instrument panel. 4. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the brake pedal support bracket until the switch housing is firmly seated against the bracket. 5. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 903 6. Release the brake pedal, but do not pull it upward. 7. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch MUST be installed. 8. Reconnect the wire harness connector (4) to the brake lamp switch (3). 9. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 10. Reconnect the battery negative cable. LATE PRODUCTION 1. Be certain that the brake lamp switch (2) plunger is pulled all the way out of the switch housing to its fully extended position. 2. Reconnect the wire harness connector (1) to the connector receptacle on the switch. 3. Depress and hold the brake pedal in the depressed position. 4. Align the tabs on the brake lamp switch locking collar with the keyed hole in the brake pedal support bracket (2). 5. Insert the tab on the brake lamp switch locking collar through the keyed hole in the support bracket until the switch housing is firmly seated against the bracket. 6. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the support bracket. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 7. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 8. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 9. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Combination Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 909 Combination Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Combination Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 912 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 913 Combination Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 914 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Combination Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 917 Combination Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 922 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 923 Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 924 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 927 Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description Hazard Warning Switch: Description and Operation Hazard Warning Switch - Description DESCRIPTION The hazard switch (3) is integral to the instrument panel switch pod (1), which is secured to the instrument panel center bezel just above the heater and air conditioner controls. A red, stencil-like International Control and Display Symbol icon for Hazard Warning identifies the hazard switch button. The remainder of the hazard switch circuitry is concealed within the instrument panel switch pod. The hazard switch button has panel lamps dimmer controlled illumination for night visibility. The switch button latches to a slightly lowered position when the hazard warning system is activated and the icon on the switch button will illuminate at an increased intensity while the turn signals and turn signal indicators are flashing. The switch button unlatches to a position flush with the other push buttons in the switch pod when the hazard warning is deactivated. All of the circuitry and components of the hazard switch are contained within a molded black plastic instrument panel switch pod housing. A single connector receptacle is integral to the back of the switch pod housing. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The hazard switch cannot be adjusted or repaired and, if ineffective or damaged, the entire instrument panel switch pod unit must be replaced. See: Sensors and Switches - Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description > Page 932 Hazard Warning Switch: Description and Operation Hazard Warning Switch - Operation OPERATION The status of the hazard switch is continually monitored by the circuitry within the instrument panel switch pod. The switch pod receives battery voltage at all times on a fused battery feed circuit, and a path to ground at all times through the instrument panel wire harness. The only other inputs to the switch pod consists of electronic communication with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the single wire Local Interface Network (LIN) data bus. Whenever the hazard switch is in its unlatched and raised position, the hazard warning system is selected and the switch pod circuitry provides a hard wired output to the Totally Integrated Power Module (TIPM). When the TIPM receives a hazard switch input it then controls hazard warning system operation and flash rate by controlling battery voltage outputs through high side drivers on the right and left, front and rear turn signal feed circuits. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hard wired circuits for the instrument panel switch pod may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the hazard warning switch or the electronic controls and communication between other modules and devices that provide some features of the hazard warning system. The most reliable, efficient, and accurate means to diagnose the hazard switch or the electronic controls and communication related to hazard warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Headlamp Dimmer Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 938 Headlamp Dimmer Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 941 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 942 Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 943 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 946 Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Headlamp Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 952 Headlamp Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 955 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 956 Headlamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 957 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 960 Headlamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 964 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal Horn Switch: Service and Repair Horn Switch - Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal > Page 967 Horn Switch: Service and Repair Horn Switch - Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 973 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 978 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 983 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 984 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 985 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 988 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 994 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 995 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 996 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 997 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1001 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1002 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 1005 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 1010 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 1015 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module Fuel Level Sensor: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 1020 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 1021 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 1022 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 1025 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 1028 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 1029 Fuel Level Sensor: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1032 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1033 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1034 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1035 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1036 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1037 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1038 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1039 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1040 Fuel Level Sensor: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1041 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1042 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1046 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1047 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (HEADLAMP AND DASH) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable. NOTE: Clean dirt from sensor area prior to removal from air box. 2. Disconnect the inlet air temperature sensor electrical connector (1). 3. Remove the inlet air temperature sensor (2) from the air box (3) by turning the sensor 1/4 turn in the counter - clockwise direction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 1050 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the inlet air temperature sensor (2) to the air box (3) by turning the sensor 1/4 turn in the clockwise direction. 2. Connect the inlet air temperature sensor electrical connector (1). 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1054 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1055 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 1058 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1062 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1063 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-MANIFOLD ABSOLUTE PRESSURE (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1064 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. MAP SENSOR WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1065 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1066 - Go to 4 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1067 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 3.5L 1. Disconnect and isolate negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Rotate sensor. 4. Lift to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1070 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 3.5L 1. Install sensor. 2. Rotate sensor into position. 3. Attach electrical connector (1) to sensor (2). 4. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 1075 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 1076 Oxygen Sensor: Locations Sensor - Oxygen 2/1 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 1077 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 1078 Oxygen Sensor: Locations Sensor - Oxygen 2/2 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 1079 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Gas) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 1082 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Gas) (Engine) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 1083 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 1084 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1085 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1086 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1087 Yes - Go to 4 - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1088 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove O2S (2) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (5). 6. Remove O2S (3) from catalytic converter (4). DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 1091 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove the O2S (5) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (2). 6. Remove O2S (3) from catalytic converter (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 1092 Oxygen Sensor: Service and Repair Installation 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (2). 3. Install the O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 1093 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (5). 3. Install O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1097 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1100 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1101 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1102 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1103 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1104 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 1110 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 1115 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1120 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 1125 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 1131 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1132 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1133 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 1136 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1140 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1141 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 1144 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations Ignition Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 1148 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Ignition Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Ignition Switch: Connector Views Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 1168 Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Operation OPERATION Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a spring-loaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY,""RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS) Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Operation. REMOTE KEYLESS ENTRY (RKE) The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Operation TIRE PRESSURE MONITORING (TPM) The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Operation. REMOTE START WITH/EXTENDED RANGE ANTENNA Further information concerning the Remote Start System. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Starting System/Description and Operation/Starting System - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI) The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. PARK SHIFT INTERLOCK The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 1169 Ignition Switch: Description and Operation Ignition Switch - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN). The WIN, along with the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch located on the face of the instrument panel just to the inboard side of the steering column. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. In addition to replacing a conventional keyed ignition switch, the WIN is an integrated electronic receiver that serves as the base station in the vehicle. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) RF communication. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged the entire WIN must be replaced See: Service and Repair/Wireless Ignition Node Receiver - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ignition Switch: Symptom Related Diagnostic Procedures FOBIK TRAPPED IN WIN The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 5. Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. 6. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. 7. Remove the lower WIN attaching screw (5). 8. Remove the lower WIN bracket attaching screw (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 1174 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 1175 Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Installation INSTALLATION NOTE: The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening. 2. Install the lower WIN bracket attaching screw (4). 3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 1176 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Install knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker Installation. 9. Connect negative battery cable. 10. If necessary, program the WIN, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1180 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1181 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 1184 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1190 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1191 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1192 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1193 Impact Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1194 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1195 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1196 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1197 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1198 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1199 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1200 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way Impact Sensor: Diagrams Left Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-LEFT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1203 Impact Sensor: Diagrams Right Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1204 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-LEFT 1 - (FRONT DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1205 Impact Sensor: Diagrams Left Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1206 Impact Sensor: Diagrams Left Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-LEFT - (FRONT END MODULE) 2 WAY Right Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1207 Left Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-LEFT 1 - (FRONT DOOR) 3 WAY Left Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1208 Right Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (FRONT DOOR) 3 WAY Right Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-RIGHT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1209 Left Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 2 WAY Right Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 1210 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Vehicle Front VEHICLE FRONT Two acceleration-type front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the back of the front end module carrier on either outboard side of the cooling module, just inboard of each front lamp unit housing within the engine compartment. The sensor housing has an integral connector receptacle (3), an integral locating and anti-rotation pin, and an integral mounting hole (2). The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the front end module wire harness. These acceleration-type front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Front Door SIDE - FRONT DOOR Two pressure-type front door side impact sensors (2) are used on this vehicle when it is equipped with the side curtain airbags or the optional seat (also known as thorax) airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with two screws and is sealed by a resilient gasket (1) to the front door module carrier on the inside of the front door. The sensors are concealed behind the front door trim panel within the passenger compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 1213 The right and left front door side impact sensors are identical in construction and calibration. The impact sensor housing has an integral connector receptacle (3), two integral mounting tabs, and an integral hood-like water shield (4) that extends through a hole in the front door module carrier into the interior of the door cavity and protects the sensor orifice from contamination. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor, which includes an electronic communication chip and the pressure sensor. The housing cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. A label on the sensor has a directional arrow and the word down imprinted upon it to provide verification of the correct sensor orientation in the vehicle. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the front door wire harness. These pressure-type front door side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Second Row Seating SIDE - SECOND ROW SEATING Two acceleration-type second row seating side impact sensors (1) are used on this vehicle when it is equipped with the side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the lower C-pillar just above the rear door opening sill within the passenger compartment. The sensor housing has an integral connector receptacle (3), an integral locating anti-rotation pin, and an integral mounting hole (2). The right and left second row seating side impact sensors are identical in construction and calibration. However, the connector orientation in the vehicle is reversed. The connector receptacle faces forward on the right side of the vehicle, and faces rearward on the left side of the vehicle. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The second row seating side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. These acceleration-type second row seating side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Third Row Seating SIDE - THIRD ROW SEATING Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 1214 Two acceleration-type third row seating side impact sensors (1) are used on this vehicle when it is equipped with the side curtain airbags and seven-passenger seating, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left quarter inner panel just above the right or left rear wheel housing within the passenger compartment. The sensor housing has an integral connector receptacle (3), an integral locating anti-rotation pin, and an integral mounting hole (2). The right and left third row seating side impact sensors are identical in construction and calibration. However, the connector orientation in the vehicle is reversed. The connector receptacle faces forward on the right side of the vehicle, and faces rearward on the left side of the vehicle. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The third row seating side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. These acceleration-type third row seating side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 1215 Impact Sensor: Description and Operation Impact Sensor - Operation Vehicle Front VEHICLE FRONT The acceleration-type front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the front passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and commands the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the sensor plus circuit. The hard wired circuits between the acceleration-type front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Front Door SIDE - FRONT DOOR The pressure-type front door side impact sensors recognize a side impact in the front door area by monitoring changes in pressure within the front door cavity, which manifests itself as a sudden pressure wave as the door collapses during an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the sensor plus circuit. The hard wired circuits between the pressure-type front door side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the pressure-type front door side impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Second Row Seating SIDE - SECOND ROW SEATING The acceleration-type second row seating side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the acceleration-type second row seating side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type second row seating side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Third Row Seating Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 1216 SIDE - THIRD ROW SEATING The acceleration-type third row seating side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the acceleration-type third row seating side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type third row seating side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Vehicle Front VEHICLE FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Service access for the front impact sensors is accomplished by reaching behind the front end module carrier (2) from the top of the engine compartment and between the inboard end of either front lamp unit housing (3) and either outboard end of the cooling module. 3. For the left front impact sensor only, remove the fresh air intake snorkel and the air filter housing from behind the front end module carrier for service access. 4. Disconnect the front end module wire harness connector (5) from the connector receptacle of the right or left front impact sensor (1). 5. Remove the screw (4) that secures the front impact sensor to the back (engine compartment side) of the front end module carrier. 6. Pull the front impact sensor straight back from the mounting location to disengage the anti-rotation pin on the base of the sensor from the clearance hole in the front end module carrier. 7. Remove the right or left front impact sensor from the engine compartment. Side - Front Door SIDE - FRONT DOOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1219 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the trim panel from the inside of the right or left front door. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the front door wire harness connector (3) from the side impact sensor (1) connector receptacle. 4. Remove the two screws (2) that secure the side impact sensor to the front door module carrier panel (4). 5. Remove the side impact sensor from the door. Side - Second Row Seating SIDE - SECOND ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Open the sliding door. 3. Remove the quarter trim panel from the lower C-pillar (1).See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 4. Disconnect the body wire harness connector (4) from the side impact sensor (3) connector receptacle. 5. Remove the screw (2) that secures the side impact sensor to the lower C-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1220 6. Pull the side impact sensor straight out from the mounting location to unsnap the anti-rotation pin on the base of the sensor from the clearance hole in the lower C-pillar. 7. Remove the side impact sensor from the vehicle. Side - Third Row Seating SIDE - THIRD ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the quarter trim panel from the quarter inner panel over the rear wheel housing (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the body wire harness connector (2) from the side impact sensor (4) above the rear wheel housing on the quarter inner panel. 4. Remove the screw (3) that secures the side impact sensor to the quarter inner panel. 5. Pull the side impact sensor straight out from the mounting location to disengage the anti-rotation pin on the base of the sensor from the clearance hole in the quarter inner panel. 6. Remove the side impact sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1221 Impact Sensor: Service and Repair Impact Sensor - Installation Vehicle Front VEHICLE FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Service access for the front impact sensors is accomplished by reaching behind the front end module carrier (2) from the top of the engine compartment and between the inboard end of either front lamp unit housing (3) and either outboard end of the cooling module. 2. Position the right or left front impact sensor (1) into the engine compartment. 3. Align and insert the anti-rotation pin on the base of the sensor into the clearance hole on the back (engine compartment side) of the front end module carrier. 4. Install and tighten the screw (4) that secures the front impact sensor to the front end module carrier. Tighten the screw to 11 Nm (97 in. lbs.). 5. Reconnect the front end module wire harness connector (5) to the connector receptacle of the front impact sensor. 6. For the left front impact sensor only, reinstall the fresh air intake snorkel and the air filter housing behind the front end module carrier. 7. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - Front Door SIDE - FRONT DOOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1222 NOTE: Be certain that the gasket between the pressure-type side impact sensor and the front door module carrier panel is in good condition and positioned on the back of the sensor. There MUST be a good seal between the sensor and the module carrier panel for the sensor to operate properly. If the gasket is in poor condition, replace the sensor. 1. Position the side impact sensor (1) to the right or left front door module carrier panel (4). When the sensor is correctly positioned, the arrow on the sensor label will be pointed toward the bottom of the door. 2. Install and tighten the two screws (2) that secure the side impact sensor to the door. Tighten the screws to 2.4 Nm (21 in. lbs.). 3. Reconnect the front door wire harness connector (3) to the sensor connector receptacle. 4. Reinstall the trim panel onto the inside of the right or left front door. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - Second Row Seating SIDE - SECOND ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1223 1. Position the side impact sensor (3) to the lower C-pillar (1). 2. Align the anti-rotation pin on the base of the sensor with the clearance hole in the lower C-pillar, then press on the sensor firmly and evenly to snap the pin into place. 3. Install and tighten the screw (2) that secures the side impact sensor to the lower C-pillar. Tighten the screw to 11 Nm (97 in. lbs.). 4. Reconnect the body wire harness connector (4) to the side impact sensor on the lower C-pillar. 5. Reinstall the quarter trim panel onto the lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - Third Row Seating SIDE - THIRD ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Position the side impact sensor (4) to the quarter inner panel above the rear wheel housing (1). 2. Align the anti-rotation pin on the base of the sensor with the clearance hole in the quarter inner panel, then press on the sensor firmly and evenly to snap the pin into place. 3. Install and tighten the screw (3) that secures the side impact sensor to the quarter inner panel. Tighten the screw to 11 Nm (97 in. lbs.). 4. Reconnect the body wire harness connector (2) to the side impact sensor on the quarter inner panel. 5. Reinstall the quarter trim panel onto the quarter inner panel over the rear wheel housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1227 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1228 Seat Belt Buckle Switch: Diagrams Connector - (BODY) 2 WAY SWITCH-SEAT BELT-DRIVER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the seat belt retractor frame (2) over the retractor spool (1) for the driver side front seat. The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description > Page 1231 Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Operation OPERATION The driver side front seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Totally Integrated Power Module (TIPM). The TIPM provides electronic driver side seat belt switch status messages to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC controls the seat belt indicator based upon the electronic driver side seat belt switch status message inputs. The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The seat belt switch is connected in series between ground and the seat belt switch sense input of the TIPM. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The TIPM monitors the condition of the driver seat belt switch circuits and will send an electronic message to illuminate the airbag indicator in the EMIC then store a Diagnostic Trouble Code (DTC) for any fault that is detected. The hard wired circuits between the driver side seat belt switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the switch or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the driver side seat belt switch or the electronic controls and communication related to seat belt switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver side front seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 1236 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC sends messages over the CAN data bus to control the illumination of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the rear edge of the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 1239 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the rear edge of the front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the blade of the sensor bracket (1) located on the inboard side near the rear of the upper inboard seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor > Page 1244 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Seat) 2 Way Seat Sensor/Switch: Diagrams Driver Seat Track Position Sensor (Seat) 2 Way Connector - (SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Seat) 2 Way > Page 1247 Seat Sensor/Switch: Diagrams Passenger Seat Track Position Sensor (Seat) 2 Way Connector - (SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-PASSENGER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations Ignition Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations > Page 1252 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 Ignition Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 Ignition Switch: Connector Views Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 1272 Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Operation OPERATION Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a spring-loaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY,""RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS) Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Operation. REMOTE KEYLESS ENTRY (RKE) The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Operation TIRE PRESSURE MONITORING (TPM) The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Operation. REMOTE START WITH/EXTENDED RANGE ANTENNA Further information concerning the Remote Start System. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Starting System/Description and Operation/Starting System - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI) The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. PARK SHIFT INTERLOCK The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 1273 Ignition Switch: Description and Operation Ignition Switch - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN). The WIN, along with the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch located on the face of the instrument panel just to the inboard side of the steering column. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. In addition to replacing a conventional keyed ignition switch, the WIN is an integrated electronic receiver that serves as the base station in the vehicle. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) RF communication. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged the entire WIN must be replaced See: Service and Repair/Wireless Ignition Node Receiver - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ignition Switch: Symptom Related Diagnostic Procedures FOBIK TRAPPED IN WIN The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 5. Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. 6. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. 7. Remove the lower WIN attaching screw (5). 8. Remove the lower WIN bracket attaching screw (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 1278 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 1279 Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Installation INSTALLATION NOTE: The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening. 2. Install the lower WIN bracket attaching screw (4). 3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 1280 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Install knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker Installation. 9. Connect negative battery cable. 10. If necessary, program the WIN, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1284 Neutral Safety Switch: Diagrams Connector (MTX) - (BODY) 3 WAY SWITCH-CLUTCH INTERLOCK (MTX) - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Maintenance/Wheels and Tires/Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1292 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1293 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: Maintenance 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1296 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1297 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1298 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1299 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Removal REMOVAL 1. Remove valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 1306 Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1310 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1313 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1314 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1315 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1316 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1317 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 1322 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 1323 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-INPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 1326 Transmission Speed Sensor: Diagrams Output Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-OUTPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 1327 Transmission Speed Sensor: Diagrams Transfer Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-TRANSFER SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1330 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Operation OPERATION The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1331 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1332 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1333 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Output Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1334 The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1335 NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Transfer Shaft Speed Sensor - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1336 The Transfer Shaft Speed Sensor (3) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Transfer Shaft Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Transfer Shaft Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 1337 The transfer shaft speed sensor (3) is located at the rear of the case (backside). It reads rotation of the front annulus/rear carrier assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1340 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1341 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1342 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1343 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1344 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1345 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Output Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1346 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1347 Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Input Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1348 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1349 Transfer Shaft Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the transfer shaft sensor (3). 2. Remove the bolt at transfer shaft sensor (1). 3. Pull up on transfer shaft sensor to remove. Transfer Shaft Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor Removal > Page 1350 1. Install a new O-ring (2). on the transfer shaft speed sensor (1). 2. Install transfer shaft speed sensor (3) into case. 3. Install bolt at transfer shaft speed sensor (1) and tighten to 12 Nm (105 in. lbs.). 4. Reconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION NOTE: Manual tri-zone temperature A/C-heater control shown. Other A/C-heater controls similar. The momentary push-button switch (1) for the rear window defogger (EBL) system is located in the A/C-heater control (2) in the center of the instrument panel. An amber indicator (3) will illuminate to indicate when the EBL system is turned on. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 1356 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 1361 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 1362 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 1363 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way Power Window Switch: Diagrams Left Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1366 Power Window Switch: Diagrams Right Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1367 Power Window Switch: Diagrams Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1368 Power Window Switch: Diagrams Driver Window/Door Lock Switch C2 (Front Door) 10 Way Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1369 Power Window Switch: Diagrams Left Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (REAR DOOR) 6 WAY Right Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1370 SWITCH-POWER WINDOW-RIGHT REAR - (REAR DOOR) 6 WAY Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Driver Window/Door Lock Switch C2 (Front Door) 10 Way Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1371 Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Passenger Window/Door Lock Switch (Except Base) (Front Door) 10 Way Connector (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1372 SWITCH-WINDOW/DOOR LOCK-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Passenger Window/Door Lock Switch (Base) (Front Door) 8 Way Connector (BASE) - (FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (BASE) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 1373 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1374 Power Window Switch: Testing and Inspection DIAGNOSIS AND TESTING For switch testing, remove the switch. See: Service and Repair/Power Window Switch - Removal. Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. MASTER WINDOW SWITCH TEST PASSENGER WINDOW SWITCH TEST Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL SWITCH - FRONT DOOR 1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. SWITCH - REAR DOOR 1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect the electrical connector. 4. Remove the switch from the handle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 1377 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION SWITCH - FRONT DOOR 1. Install the switch by snapping into place. 2. Connect switch wire connector. 3. Install the switch to the door trim panel. 4. Connect the battery negative cable. SWITCH - REAR DOOR 1. Connect the electrical connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1382 Washer Fluid Level Switch: Diagrams Connector - (FRONT END MODULE) 2 WAY SENSOR-WASHER FLUID LEVEL-FRONT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir on the upper left corner of the cooling module on the Front End Module (FEM). Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the FEM wire harness. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description > Page 1385 Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON request message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level indicator or the electronic controls or communication between other modules and devices that provide some features of the washer system. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the washer reservoir from the back of the cooling module on the Front End Module (FEM). See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Removal. 3. Disconnect the FEM wire harness connector from the washer fluid level switch connector receptacle (3) on the back of the reservoir. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir. Care must be taken not to damage the reservoir. 5. Remove the switch from the washer reservoir. 6. Remove the rubber grommet seal from the switch mounting hole in the washer reservoir and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal > Page 1388 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Installation INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented upward. 4. Reconnect the Front End Module (FEM) wire harness connector (3) to the switch connector receptacle. 5. Reinstall the washer reservoir onto the back of the cooling module on the FEM. See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Connector - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-RIGHT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Connector - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-RIGHT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description Wiper Switch: Description and Operation Right Multifunction Switch - Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. - Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 1397 - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides one momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 1398 Wiper Switch: Description and Operation Right Multifunction Switch - Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional analog switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard-wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1399 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See: Service and Repair/Right Multifunction Switch - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1400 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal Wiper Switch: Service and Repair Right Multifunction Switch - Removal REMOVAL WARNING: To avoid personal or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). 6. Remove the switch from the clockspring (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal > Page 1403 Wiper Switch: Service and Repair Right Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). Tighten the screw to 1 Nm (10 in. lbs.). 4. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Specifications Alignment: Specifications Curb Height Specifications CURB HEIGHT SPECIFICATIONS NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. Front - On each side of the vehicle, measure the distance (2) from the flat surface behind the PLP hole (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Specifications > Page 1409 Rear - On each side of the vehicle, measure the distance (2) from the flat surface below the rear toe adjustment cam bolt (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. Compare the measurements to specifications listed in the CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1410 Alignment: Description and Operation DESCRIPTION Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when Chrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front - Camber (with cradle shift or service adjustment bolt package) - Caster (limited adjustment with cradle shift) - Toe Rear - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement for additional information. See: Service and Repair/Curb Height Measurement Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is known as negative camber. Outward tilt (1) is known as Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1411 positive camber. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. - Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7° and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2). CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. - Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. To achieve the cross caster reading, subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2). TOE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1412 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. - Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equal distant. TOE-OUT ON TURNS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1413 Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1414 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). - Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. See: WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. See: Specifications/Wheel Alignment Specifications REAR CAMBER Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, rear camber is not considered an adjustable angle. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles but some adjustment can be made. Camber and caster should be checked to ensure they meet vehicle specifications. See: Specifications/Wheel Alignment Specifications If individual front camber or caster is found not to meet alignment specifications, each can be adjusted by shifting the front crossmember or by using an available service adjustment bolt package. If an adjustment bolt package installation is necessary, inspect the suspension components for any signs of damage or bending first. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. ADJUSTMENT BY SHIFTING CROSSMEMBER CAUTION: Always use care when shifting crossmember to avoid damaging other components on the vehicle. 1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow movement of the crossmember. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal 2. Loosen the bolts fastening the fore/aft crossmember to the frame just enough to allow movement of the crossmember. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1417 CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine mounts are attached to the front crossmember and fore/aft crossmember and should be inspected following the crossmember shift to make sure they are properly aligned. 3. Shift front crossmember as necessary (See following tables) to bring camber or caster into specifications. When shifting crossmember, use care not to move other angles (camber or caster) that are within specifications, out of specifications. 4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to specifications. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure camber and caster. If camber and caster are within specifications, proceed to TOE. If camber cannot be brought into specifications, perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. See: 2. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1). CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a punch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1418 3. Remove the original nuts (3, 4) and upper (1) and lower (6) bolts attaching the strut clevis bracket (2) to the knuckle (5). 4. Separate the knuckle (5) from the strut clevis bracket (2) and position knuckle so it is out of the way of the strut. Use care not to overextend the brake flex hose or axle half shaft. CAUTION: When slotting the bottom mounting hole (3) on the strut clevis bracket (4), do not enlarge the hole beyond the indentations (2) on the sides of the strut clevis bracket. 5. Using an appropriate grinder and grinding wheel, slot the bottom hole (3) in both sides of the strut clevis bracket (4). CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts. Only the service package bolts and dog bone washers must be used to attach the knuckle to the strut once the mounting hole is slotted. 6. Position the strut clevis bracket in line with the upper end of the knuckle, aligning the mounting holes. Install the two service package bolts. Be sure to place the bolt with the eccentric cam in the bottom (slotted) hole on strut clevis bracket. 7. Install the dog bone washers provided in the service package and nuts on the replacement bolts. Tighten each nut just enough to hold the knuckle in position while adjusting camber, but still allows the knuckle to move in the clevis bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1419 8. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Perform the above procedure to opposite side strut as required. 10. Lower the vehicle and jounce the front and rear of the vehicle. 11. Adjust the front camber to the preferred setting using the cam bolt in the lower mounting hole. Once camber is set to specifications, tighten the upper and lower strut service package bolt nuts to 140 Nm (103 ft. lbs.). Again jounce the front and rear of the vehicle, then verify the camber settings. 12. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to FRONT TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting front toe to the preferred specifications REAR TOE NOTE: Perform the following at each rear wheel as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1420 1. While holding the cam bolt head (4) stationary, loosen the toe link mounting cam bolt nut (3). 2. Rotate the cam bolt head (4) left or right until the rear wheel toe for that rear wheel is set to the preferred specification. See: Specifications/Wheel Alignment Specifications 3. While holding the cam bolt head (4) stationary, tighten the toe link mounting cam bolt nut (3) to 100 Nm (74 ft. lbs.). FRONT TOE NOTE: Perform the following at each front wheel as necessary. CAUTION: Do not twist the inner tie rod-to-steering gear boot (bellows) while turning the inner tie rod during front toe adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod. 1. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the other until the front wheel toe is set to the preferred specification. See: Specifications/Wheel Alignment Specifications 2. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 3. Make sure the inner tie rod-to-steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. 4. Remove the steering wheel clamp. 5. Remove the alignment equipment. 6. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1421 Alignment: Service and Repair Curb Height Measurement CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. Front - On each side of the vehicle, measure the distance 2 from the flat surface behind the PLP hole 1 to the floor or alignment rack/lift Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1422 runway surface. It may be necessary to measure to the bottom of a straight edge 3, placed from lift runway to runway, to get an accurate measurement. 3. Rear - On each side of the vehicle, measure the distance 2 from the flat surface below the rear toe adjustment cam bolt 1 to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge 3, placed from lift runway to runway, to get an accurate measurement. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Fuel Flow Leakdown Less than 10 psi in 5 minutes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. FUEL PUMP OPERATION 1. Ignition on, engine not running. 2. With a scan tool, actuate the Fuel System test. NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly with no excessive noise. If the pump has excessive noise such as grinding, the pump should be replaced. CAUTION: Stop All Actuations. Does the Fuel Pump sound to be operate normally? Yes - Go to 2 No - Go to 7 2. FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge. 3. Ignition on, engine not running. 4. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Choose a conclusion that best matches your fuel pressure reading. Below Specification - Go to 3 Within Specification - Test Complete. Above Specification - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1429 Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special tool #6539 (5/16") or #6631(3/8") fuel line adapter and the fuel pressure gauge between the fuel supply line and the fuel pump module. 4. Ignition on, engine not running. 5. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Is the fuel pressure within specification now? Yes - Repair/replace fuel supply line as necessary. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. CHECKING FUEL TANK SIPHON HOSE AND FUEL LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the Fuel Pump Module and the Fuel Tank Module. 3. Inspect the following fuel components: Fuel line and siphon hose between the Fuel Pump Module and the Fuel Tank Module. Look for disconnected and/or damaged lines or hoses. - Fuel Pressure Regulator not properly seated in the module. Were the above items in good working condition? Yes - Go to 6 No - Repair or replace as necessary. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. CHECKING THE FUEL PUMP INLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1430 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Inlet and the bottom of the fuel tank for debris that could cause the fuel pump inlet to be plugged. Is the Fuel Pump Inlet plugged? Yes - Repair/Replace as necessary. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP MOTOR GROUND CIRCUIT 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light to battery voltage, probe the Fuel Pump Motor Ground circuit in the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Does the test light illuminate brightly. Yes - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Motor Ground circuit. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1431 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1432 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1433 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1434 Fuel Pressure: Testing and Inspection Fuel Delivery System Output - Flow Test FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure. - Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. - Use extreme caution when connecting and disconnecting fuel lines. Considerable fuel leakage may occur when servicing the fuel system. Wear protective eyewear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair or replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester 8978A. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1435 Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly 8978A-1 Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: - Open the Fuel System Isolation Valve (1). - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1436 - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 1. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. 2. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa ± 34 kPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 kPa ± 34 kPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Ignition on, engine not running. 2. With the scan tool, actuate the fuel pump. 3. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. 4. Turn the ignition off. 5. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. Does the amount of fuel in the reservoir meet or exceed the specification? Yes - Test complete. No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Disengage the air filter housing clips (1). 2. Slide the air filter housing cover (2) forward slightly to disengage tabs from the bottom of the air filter housing. 3. Remove air cleaner element from air cleaner housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1442 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install air filter element into the bottom half of the air filter housing. 2. Slide the air filter housing cover (2) rearward to engage the tabs into the bottom half of the air filter housing. 3. Reengage the air filter housing clips (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 2.4L The firing order is 1-3-4-2. 3.5L The firing order is 1-2-3-4-5-6. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal Spark Plug Tube: Service and Repair Removal REMOVAL 1. Remove cylinder head cover(s). See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal 2. Using suitable locking pliers, remove the tube (1) from the cylinder head and discard tube. 3. Clean area around spark plug with Mopar(R) Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal > Page 1455 Spark Plug Tube: Service and Repair Installation INSTALLATION 1. Apply Mopar(R) Stud and Bearing Mount to a new tube (1) approximately 1 mm (0.039 in.) from the end of tube, in a 3 mm (0.118 in.) wide area. 2. Install sealer end of tube (1) into the cylinder head. Then carefully install the tube (1) using a hardwood block and mallet. Install the tube (1) until it is seated into the bottom of the bore. 3. For spark plug tube (1) seal replacement, See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 4. Install cylinder head cover(s). See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation - INSTALLATION) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Ratio .............................................................................................................................. ............................................................................ 10:1 Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1459 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the TIPM. 5. Install a suitable compression test gauge into the number 1 spark plug hole in cylinder head. 6. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Procedures Timing Belt: Procedures TIMING BELT 1. Remove front timing belt cover See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 2. Inspect both sides of the timing belt. Replace belt if any of the following conditions exist: a. Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail. b. Cracks on rubber back. c. Cracks or peeling of canvas. d. Cracks on rib root. e. Cracks on belt sides. f. Missing teeth. g. Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. h. Vehicle mileage or time at component maintenance requirement. See: 3. If none of the above conditions are seen on the belt, the front timing belt cover can be installed See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Procedures > Page 1464 Timing Belt: Removal and Replacement Timing Belt & Sprockets - Removal TIMING BELT 1. Perform fuel pressure release procedure. See: Filters/Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect negative battery cable. 3. Remove both cylinder head covers. 4. Remove the front timing belt cover See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 5. Mark belt running direction, if timing belt is to be reused. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. 6. Rotate engine clockwise until crankshaft mark aligns with the TDC mark on oil pump housing and the camshaft sprocket timing marks are aligned with the marks on the rear cover. 7. Remove the timing belt tensioner and remove timing belt. 8. Inspect the tensioner for fluid leakage. 9. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace the arm and pulley assembly. 10. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This ensures proper pin orientation when tensioner is installed on the engine. a. Place the tensioner into a vise and SLOWLY compress the plunger. Total bleed down of tensioner should take about 5 minutes. b. When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed. Timing Belt & Sprockets - Installation TIMING BELT CAUTION: The 3.5L is NOT a freewheeling engine. Therefore, the valve train rocker assemblies must be removed before attempting to rotate either crankshaft or camshafts independently of each other. CAUTION: If camshafts have moved from the timing marks, always rotate camshaft towards the direction nearest to the timing marks (DO NOT TURN CAMSHAFTS A FULL REVOLUTION OR DAMAGE to valves and/or pistons could result). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Procedures > Page 1465 TIMING GEAR ALIGNMENT 1. Align the crankshaft sprocket (10) with the TDC mark (9) on the oil pump cover. 2. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover. 3. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket and maintain tension on the belt as it is positioned around the tensioner pulley (11). NOTE: It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner. See Timing Belt Removal for tensioner compression procedure See: Timing Belt & Sprockets - Removal . 4. Hold the tensioner pulley (11) against the belt and install the reset (pinned) timing belt tensioner (2) into the housing. Tighten attaching bolts to 28 Nm (250 in. lbs.). 5. When tensioner (12) is in place, pull the retaining pin to allow the tensioner to extend to the pulley bracket. 6. Rotate the crankshaft sprocket (10) two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure. 7. Install the front timing belt cover See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation. 8. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations TIMING BELT CAUTION: The 3.5L is NOT a freewheeling engine. Therefore, the valve train rocker assemblies must be removed before attempting to rotate either crankshaft or camshafts independently of each other. CAUTION: If camshafts have moved from the timing marks, always rotate camshaft towards the direction nearest to the timing marks (DO NOT TURN CAMSHAFTS A FULL REVOLUTION OR DAMAGE to valves and/or pistons could result). TIMING GEAR ALIGNMENT 1. Align the crankshaft sprocket (10) with the TDC mark (9) on the oil pump cover. 2. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover. 3. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket and maintain tension on the belt as it is positioned around the tensioner pulley (11). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION ACCESSORY DRIVE BELT - WORLD ENGINE The accessory drive belt is a Poly-V type belt. On the 2.4L engine, the accessory drive belt drives the generator, P/S pump and air conditioning compressor. ACCESSORY DRIVE BELT -3.5L Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1472 On the 3.5L, the accessory drive belt drives the generator, P/S pump, and A/C compressor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1473 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELTS Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. ACCESSORY DRIVE BELT DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures Serpentine Accessory Drive Belt - Cleaning CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Serpentine Accessory Drive Belt - Inspection INSPECTION Belt replacement under any or all of the following conditions is required: - Excessive wear - Frayed cords - Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not. NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1476 Drive Belt: Removal and Replacement Serpentine Accessory Drive Belt - Removal 3.5L ENGINE ACCESSORY DRIVE BELT -3.5L 1. Raise vehicle on hoist. 2. Remove RH wheelhouse splash shield.See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 3. Rotate accessory drive belt tensioner (3) clockwise to allow enough slack to remove accessory drive belt (5). Serpentine Accessory Drive Belt - Installation 3.5L ENGINE ACCESSORY DRIVE BELT -3.5L Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1477 1. Position accessory drive belt (5) on all pulleys except generator (6). 2. Rotate accessory drive belt tensioner (3) clockwise. 3. Position accessory drive belt (5) on generator pulley (6). 4. Slowly release accessory drive belt tensioner (3). 5. Install RH wheelhouse splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield Installation 6. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Disengage the air filter housing clips (1). 2. Slide the air filter housing cover (2) forward slightly to disengage tabs from the bottom of the air filter housing. 3. Remove air cleaner element from air cleaner housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1484 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install air filter element into the bottom half of the air filter housing. 2. Slide the air filter housing cover (2) rearward to engage the tabs into the bottom half of the air filter housing. 3. Reengage the air filter housing clips (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Description and Operation Cabin Air Filter: Description and Operation DESCRIPTION Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin. The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures Cabin Air Filter: Procedures WARNING: Do not remove the A/C air filter while the blower is operating or personal injury may result. The A/C air filter is located in the fresh air inlet behind the glove box. Perform the following steps to replace the filter: 1. Open the glove box and remove all contents. 2. Push the retaining tab on each side of the glove box inward while gently pulling the glove box door outward until both tabs clear the door opening in the instrument panel. 3. Pivot the glove box downward. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1490 4. Disengage the two retaining tabs that secure the filter cover to the HVAC housing and remove the cover. 5. Remove the A/C air filter by pulling it straight out of the housing. 6. Install the A/C air filter with the arrow on the filter pointing toward the floor. When installing the filter cover, make sure the retaining tabs fully engage the cover. CAUTION: The A/C air filter is labeled with an arrow to indicate airflow direction through the filter. Failure to install the filter properly will result in the need to replace it more often. 7. Reinstall the glove box door. Make sure that the hinges are seated fully as you raise the door. Otherwise, the door latch will not align properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1491 Cabin Air Filter: Removal and Replacement Particulate Air Filter - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Always make sure the A/C-heater system is turned off and that the ignition switch is in the OFF position prior to servicing the particulate air filter. Never place fingers or other objects into the filter opening of the HVAC housing. Failure to follow this warning may result in serious injury. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. Particulate Air Filter - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1492 INSTALLATION NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE: LHD model shown in illustrations. 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair FLUID AND FILTER SERVICE FLUID/FILTER SERVICE (RECOMMENDED) NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled MOPAR(R) ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Remove nuts at the oil filter. 4. Install a new filter and nuts, tighten to 5 Nm (40 in. lbs.). 5. Install the fluid filter oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 6. Clean the oil pan and magnet. Reinstall pan using new MOPAR(R) Silicone Adhesive sealant. Tighten oil pan bolts to 6 Nm (50 in. lbs.). 7. Pour four Quarts of MOPAR(R) ATF+4 through the dipstick opening. 8. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 in.) below the lowest mark on the dipstick. 10. Recheck the fluid level after the transaxle has reached normal operating temperature 82° C (180°F). Refer to Fluid Level and Condition Check for the proper fluid fill procedure See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid Level and Condition Check. 11. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures Oil Filter: Procedures ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. See: WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. TO CHANGE ENGINE OIL 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Open hood, remove engine oil fill cap (1). 4. Raise vehicle on hoist. 5. Place a suitable drain pan under crankcase drain. 6. Remove oil pan drain plug (1) from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (2). 8. Install drain plug (1) in crankcase. Tighten oil pan drain plug to 27 Nm (20 ft. lbs.). 9. Install new oil filter (2). 10. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1504 11. Fill crankcase with specified type and amount of engine oil. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Description and Operation 12. Install oil fill cap (1). 13. Start engine and inspect for leaks. 14. Turn engine off and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. When replacing oil filter, use a Mopar(R) filter or equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING above. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1505 Oil Filter: Removal and Replacement Engine Oil Filter - Removal REMOVAL NOTE: When servicing the oil filter, avoid deforming the filter can. Install the remove/install tool band strap against the base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using a suitable oil filter wrench, unscrew filter (2) from base and discard. Engine Oil Filter - Installation INSTALLATION All engines are equipped with a high quality full-flow, disposable type oil filter (2). When replacing oil filter, use a Mopar(R) filter or equivalent. 1. Wipe base clean, then inspect gasket contact surface. 2. Lubricate gasket of new filter with clean engine oil. 3. Install and tighten oil filter (2) to 16 Nm (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary. 4. Start engine and check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Removal WATER INLET TUBE The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing. 1. Drain cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 2. Remove the coolant adapter and secondary thermostat See: Engine, Cooling and Exhaust/Cooling System/Thermostat/Service and Repair/Engine Coolant Thermostat - Removal. 3. Raise and support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal > Page 1511 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Installation WATER INLET TUBE 1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2. Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment. 5. Install secondary thermostat and coolant adapter See: Engine, Cooling and Exhaust/Cooling System/Thermostat/Service and Repair/Engine Coolant Thermostat - Installation. 6. Tighten coolant tube nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description Hose/Line HVAC: Description and Operation A/C Discharge Line - Description DESCRIPTION NOTE: 2.7L shown. Other engines similar. The A/C discharge line (2) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the metal gaskets (1) and rubber O-ring seals (3) used on the fittings. The O-ring seals are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is disconnected. The A/C discharge line cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1516 Hose/Line HVAC: Description and Operation A/C Liquid Line - Description DESCRIPTION NOTE: A/C liquid and suction line assembly with rear A/C shown. Front A/C only line assembly similar. The A/C liquid line is serviced in two sections. The front section of the A/C liquid line is the refrigerant line that carries liquid refrigerant from the A/C condenser to the A/C receiver/drier and is only serviced as an assembly with receiver/drier See: Heating and Air Conditioning/Receiver Dryer/Description and Operation/Front A/C Receiver Drier - Description. The rear section of the A/C liquid line (1) carries liquid refrigerant from the A/C receiver/drier to the A/C expansion valve and includes the high side service port (2) and a fitting for the A/C pressure transducer (4). The rear section of the A/C liquid line is only serviced as an assembly with the A/C suction line (5). When equipped with rear A/C, the A/C liquid and suction line assembly includes connections for the underbody refrigerant lines (3). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid and suction line assembly has no serviceable parts except for the metal gaskets, rubber O-ring seals and the service port valve cores. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is disconnected. The A/C liquid and suction line assembly cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1517 Hose/Line HVAC: Description and Operation A/C Suction Line - Description DESCRIPTION NOTE: A/C Suction line for 2.7L engine shown. Other engines similar. The A/C suction line carries refrigerant from the A/C expansion valve to the A/C compressor and is serviced in two sections. The upper section of the A/C suction line (1) includes the low side service port (2) and is only serviced as an assembly with the rear A/C liquid line (6). When equipped with rear A/C, the A/C liquid and suction line assembly includes connections for the underbody refrigerant lines (3). The lower section of the A/C suction line (7) connects to the upper section of the suction line and the connections are sealed by use of metal gaskets (5) and rubber O-ring seals (4) NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The lower A/C suction line and the A/C liquid and suction line assembly has no serviceable parts except for the metal gaskets, rubber O-ring seals and the service port valve cores. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid and suction line assembly is disconnected. The lower A/C suction line and the A/C liquid and suction line assembly cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1518 Hose/Line HVAC: Description and Operation A/C Underbody Lines - Description DESCRIPTION Models equipped with the rear heating-A/C system use metal lines attached to the vehicle underbody to carry refrigerant and engine coolant to and from the rear A/C evaporator and heater core. The underbody A/C lines (1) are connected to the front A/C suction and liquid lines and to the rear A/C expansion valve extension tubes using nut type fittings (4) and O-ring seals. The underbody heater lines (2) are connected to the front heater hoses and the rear heater core using spring type clamps (3). The underbody lines are retained to the vehicle by seven plastic mounting brackets (5). NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. The underbody lines have no serviceable parts except for the refrigerant line rubber O-ring seals and metal spring clamps. The O-ring seals used on the refrigerant line connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the underbody refrigerant lines are disconnected. The underbody lines cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1519 Hose/Line HVAC: Description and Operation A/C Underbody Extension Lines - Description DESCRIPTION Models equipped with the rear heating-A/C system use metal lines attached to the vehicle underbody to carry refrigerant and engine coolant to and from the rear A/C evaporator and heater core. The underbody A/C lines are connected to the front A/C suction and liquid lines by use of underbody A/C extension lines (2). The underbody A/C extension lines are connected to the front and underbody refrigerant lines with nut type fittings (1 and 3) and O-ring seals. NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. The underbody A/C extension lines have no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the refrigerant line connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the underbody refrigerant lines are disconnected. The underbody A/C extension lines cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Remove the nut (5) that secures the A/C discharge line (1) to the condenser tapping block (2) located on the right side of the condenser. 4. Disconnect the A/C discharge line from the tapping block. NOTE: 2.7L shown. Other engines similar. 5. Remove the nut (3) that secures the A/C discharge line (1) to the A/C compressor (2). 6. Disconnect the A/C discharge line from the A/C compressor and remove the discharge line from the engine compartment. 7. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened discharge line fittings and the compressor and condenser ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1522 Hose/Line HVAC: Service and Repair A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: 2.7L shown. Other engines similar. 1. Remove the tape or plugs from the opened discharge line fittings and the compressor and condenser ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C discharge line (1) into the engine compartment and connect it to the A/C compressor (2). 4. Install the nut (3) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 5. Connect the A/C discharge line (1) to the condenser tapping block (2). 6. Install the nut (5) that secures the A/C discharge line to the tapping block. Tighten the nut to 20 Nm (15 ft. lbs.). 7. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1523 CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 8. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 10. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1524 Hose/Line HVAC: Service and Repair A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: The rear A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 6. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal and gasket. 7. Disconnect the lower portion of the A/C suction line from the A/C liquid and suction line assembly See: A/C Suction Line - Removal. 8. Remove the bolt (3) that secures the rear section of the A/C suction line (2) to the right front frame rail. 9. Lower the vehicle. 10. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1525 NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required. 11. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and power steering fluid is not required. 12. Remove the engine coolant reservoir from the right side of the engine compartment and position it out of the way See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle Removal. 13. Remove the power steering fluid reservoir from the right front strut tower and position it out of the way See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 14. If equipped with ABS, remove the ABS control module and pump assembly and position the brake lines out of the way as necessary See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) Installation. 15. Disconnect the wire harness connector from the A/C pressure transducer (7) located on the A/C liquid line and remove the transducer if required See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Service and Repair/Front A/C Pressure Transducer - Removal. 16. If equipped with rear A/C, disconnect the rear A/C extension lines from the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Removal. 17. Remove the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. 18. Remove the nut (5) that secures the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). 19. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and discard the O-ring seals. 20. Remove the A/C liquid and suction line assembly from the engine compartment. 21. Install plugs in, or tape over all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1526 Hose/Line HVAC: Service and Repair A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. 1. Remove the tape or plugs from all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. 2. Lubricate new rubber O-rings with clean refrigerant oil and install them and new gaskets onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C liquid and suction line assembly (1) into the engine compartment. 4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 6. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 7. If equipped with rear A/C, connect the rear A/C extension lines to the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Installation. 8. If removed, lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the fitting for the A/C pressure transducer (7) located on the A/C liquid line and install the pressure transducer. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1527 9. Connect the wire harness connector to the A/C pressure transducer. 10. If equipped with ABS, install the ABS control module and pump assembly See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. 11. Install the power steering fluid reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. 12. Install the engine coolant reservoir See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation. 13. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 14. Raise and support the vehicle. 15. Install the bolt (3) that secures the upper portion of the A/C suction line (2) to the right front frame rail. Tighten the bolt securely 16. Install the lower portion of the A/C suction line to the upper suction line See: A/C Suction Line - Installation. 17. Connect the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 18. Install the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). Tighten the nut to 20 Nm (15 ft. lbs.). 19. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If equipped with ABS, bleed the brake system See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1528 23. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 24. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 25. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1529 Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Remove the nut (5) that secures the A/C discharge line (1) to the condenser tapping block (2) located on the right side of the condenser. 4. Disconnect the A/C discharge line from the tapping block. NOTE: 2.7L shown. Other engines similar. 5. Remove the nut (3) that secures the A/C discharge line (1) to the A/C compressor (2). 6. Disconnect the A/C discharge line from the A/C compressor and remove the discharge line from the engine compartment. 7. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened discharge line fittings and the compressor and condenser ports. A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1530 and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: 2.7L shown. Other engines similar. 1. Remove the tape or plugs from the opened discharge line fittings and the compressor and condenser ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C discharge line (1) into the engine compartment and connect it to the A/C compressor (2). 4. Install the nut (3) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 5. Connect the A/C discharge line (1) to the condenser tapping block (2). 6. Install the nut (5) that secures the A/C discharge line to the tapping block. Tighten the nut to 20 Nm (15 ft. lbs.). 7. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 8. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 10. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1531 A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: The rear A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 6. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal and gasket. 7. Disconnect the lower portion of the A/C suction line from the A/C liquid and suction line assembly See: A/C Suction Line - Removal. 8. Remove the bolt (3) that secures the rear section of the A/C suction line (2) to the right front frame rail. 9. Lower the vehicle. 10. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1532 heat shield retaining nuts is not required. 11. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and power steering fluid is not required. 12. Remove the engine coolant reservoir from the right side of the engine compartment and position it out of the way See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle Removal. 13. Remove the power steering fluid reservoir from the right front strut tower and position it out of the way See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 14. If equipped with ABS, remove the ABS control module and pump assembly and position the brake lines out of the way as necessary See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) Installation. 15. Disconnect the wire harness connector from the A/C pressure transducer (7) located on the A/C liquid line and remove the transducer if required See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Service and Repair/Front A/C Pressure Transducer - Removal. 16. If equipped with rear A/C, disconnect the rear A/C extension lines from the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Removal. 17. Remove the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. 18. Remove the nut (5) that secures the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). 19. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and discard the O-ring seals. 20. Remove the A/C liquid and suction line assembly from the engine compartment. 21. Install plugs in, or tape over all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1533 NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. 1. Remove the tape or plugs from all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. 2. Lubricate new rubber O-rings with clean refrigerant oil and install them and new gaskets onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C liquid and suction line assembly (1) into the engine compartment. 4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 6. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 7. If equipped with rear A/C, connect the rear A/C extension lines to the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Installation. 8. If removed, lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the fitting for the A/C pressure transducer (7) located on the A/C liquid line and install the pressure transducer. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 9. Connect the wire harness connector to the A/C pressure transducer. 10. If equipped with ABS, install the ABS control module and pump assembly See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. 11. Install the power steering fluid reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. 12. Install the engine coolant reservoir See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1534 13. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 14. Raise and support the vehicle. 15. Install the bolt (3) that secures the upper portion of the A/C suction line (2) to the right front frame rail. Tighten the bolt securely 16. Install the lower portion of the A/C suction line to the upper suction line See: A/C Suction Line - Installation. 17. Connect the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 18. Install the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). Tighten the nut to 20 Nm (15 ft. lbs.). 19. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If equipped with ABS, bleed the brake system See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 23. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 24. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 25. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. A/C Suction Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1535 Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: The A/C suction line is serviced in two sections. NOTE: LHD model shown in illustrations. Upper A/C Suction Line NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the rear A/C liquid line. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 6. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal and gasket. 7. Disconnect the lower portion of the A/C suction line from the A/C liquid and suction line assembly See: A/C Suction Line - Removal. 8. Remove the bolt (3) that secures the rear section of the A/C suction line (2) to the right front frame rail. 9. Lower the vehicle. 10. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1536 11. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and power steering fluid is not required. 12. Remove the engine coolant reservoir from the right side of the engine compartment and position it out of the way See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle Removal. 13. Remove the power steering fluid reservoir from the right front strut tower and position it out of the way See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 14. If equipped with ABS, remove the ABS control module and pump assembly and position the brake lines out of the way as necessary See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) Installation. 15. Disconnect the wire harness connector from the A/C pressure transducer (7) located on the A/C liquid line and remove the transducer if required See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Service and Repair/Front A/C Pressure Transducer - Removal. 16. If equipped with rear A/C, disconnect the rear A/C extension lines from the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Removal. 17. Remove the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. 18. Remove the nut (5) that secures the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). 19. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and discard the O-ring seals. 20. Remove the A/C liquid and suction line assembly from the engine compartment. 21. Install plugs in, or tape over all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. Lower A/C Suction Line Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1537 NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (2) that secures the lower A/C suction line (3) to the upper A/C suction line (1). 6. Disconnect the lower A/C suction line to the upper A/C suction line and remove and discard the O-ring seal and gasket. NOTE: 2.7L shown. Other engines similar. 7. Remove the nut (2) that secures the lower A/C suction line (1) to the A/C compressor (3). 8. Disconnect the lower A/C suction line from the A/C compressor and remove the lower line from the engine compartment. 9. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over all the opened suction line fittings and the compressor port. A/C Suction Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1538 NOTE: LHD model shown in illustrations. Upper A/C Suction Line 1. Remove the tape or plugs from all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. 2. Lubricate new rubber O-rings with clean refrigerant oil and install them and new gaskets onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C liquid and suction line assembly (1) into the engine compartment. 4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 6. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 7. If equipped with rear A/C, connect the rear A/C extension lines to the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Installation. 8. If removed, lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the fitting for the A/C pressure transducer (7) located on the A/C liquid line and install the pressure transducer. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 9. Connect the wire harness connector to the A/C pressure transducer. 10. If equipped with ABS, install the ABS control module and pump assembly See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. 11. Install the power steering fluid reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. 12. Install the engine coolant reservoir See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1539 13. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 14. Raise and support the vehicle. 15. Install the bolt (3) that secures the upper portion of the A/C suction line (2) to the right front frame rail. Tighten the bolt securely 16. Connect the lower portion of the A/C suction line to the A/C liquid and suction line assembly See: A/C Suction Line Installation. 17. Connect the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 18. Install the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). Tighten the nut to 20 Nm (15 ft. lbs.). 19. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If equipped with ABS, bleed the brake system See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 23. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 24. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 25. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Lower A/C Suction Line Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1540 NOTE: 2.7L shown. Other engines similar. 1. Position the lower A/C suction line (1) into the engine compartment. 2. Remove the tape or plugs from the suction line fittings and the compressor port. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the lower A/C suction line to the A/C compressor (3). 5. Install the nut (2) that secures the lower A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 6. Connect the lower portion of the A/C suction line (3) to the upper suction line (1) 7. Install the nut (2) that secures the lower portion of the A/C suction line to the upper suction line. Tighten the nut to 20 Nm (15 ft. lbs.). 8. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 9. Lower the vehicle. 10. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 11. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 12. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 13. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. A/C Underbody Lines - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1541 WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: To prevent any contaminates from entering the rear heating-A/C system, make sure that the area around the underbody line connections is clean of any dirt or foreign residue prior to disconnecting the lines. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Raise and support the vehicle. 5. Remove the rear section of the exhaust system See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe Removal. 6. Remove the exhaust heat shields as necessary to gain access to the underbody lines See: Engine, Cooling and Exhaust/Exhaust System/Heat Shield/Description and Operation/Description. NOTE: Replacement of the front heater hoses will be required if the hose ends are cut for removal. 7. Release the spring type hose clamps (2) and disconnect the front heater hoses (1) from the underbody heater lines (4). 8. Loosen the fitting nuts (6) that secure the underbody refrigerant lines (5) to the front A/C liquid and suction lines (7). 9. Disconnect the front A/C liquid and suction lines from the underbody refrigerant lines and remove and discard the O-ring seals. 10. Disengage the front A/C liquid and suction lines from the front underbody refrigerant line bracket (3). 11. Remove the two nuts (3) and one screw (1) that secure the underbody line shield (2) to the vehicle underbody and remove the shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1542 CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater tubes when disconnecting the connections. Excessive force may damage or deform the tubes and or lines, causing an engine coolant leak. NOTE: Replacement of the rubber heater hose ends will be required if the rubber hoses are cut for removal. 12. Release the spring type hose clamps (4) and disconnect the underbody heater lines (5) from the rear heater core tubes located behind the right rear wheel housing. 13. Lower the underbody heater lines and drain any residual coolant from the lines into a suitable container. 14. Loosen the fitting nuts (1) that secure the underbody refrigerant lines (7) to the underbody refrigerant extension lines and sealing plate (2 and 6). 15. Disconnect the underbody refrigerant lines from underbody refrigerant extension lines and remove and discard the O-ring seals. 16. Remove the nut (3) that secures the underbody refrigerant extension lines and sealing plate to the rear A/C expansion valve. 17. Disconnect the extension lines and sealing plate from the rear A/C expansion valve and remove and discard the O-ring seals. 18. Disconnect the rear ABS wire harness lead and bracket (4) from the right side of the body (3) to gain clearance to partially lower the right side of the rear cradle. NOTE: It is not necessary to disconnect the brake line to remove it from the brackets. 19. Remove the two bolts (6) that secure the right rear brake line (1) to the two brackets (2 and 5) and remove the brake line from the brackets to gain clearance to partially lower the right side of the rear cradle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1543 NOTE: Illustration shown with rear body cradle removed for clarity. 20. Remove the lower right rear shock retaining bolt See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over Removal. WARNING: Be sure to properly support the rear cradle before removing the right side retaining bolts. Failure to follow this warning may result in serious or fatal injury. 21. Support the right side of the rear cradle with a suitable jack stand and remove the bolts that secure the right side of the cradle to the body See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal. CAUTION: Use care not to damage the ABS wire lead or the brake line when lowering the rear cradle for clearance. 22. Carefully lower the jack stand until the right side of the rear cradle (supported by the stand) is approximately 76-101 mm (3-4 in.) below the body. This will allow access to remove the underbody line assembly. 23. Remove the nut (5) that secures the underbody line bracket (4) to the stud located near the center of the underbody (6). 24. Disengage the remainder of the underbody line brackets (1, 2, and 7) from the studs located underneath the vehicle. 25. Rotate and tilt the underbody lines (3) as necessary and remove the lines from the vehicle. 26. Install plugs in, or tape over all the opened refrigerant line fittings and the rear expansion valve ports. 27. If required, place the extension lines and sealing plate (1) on a workbench, remove the nylon retaining clip (4) that secures the suction extension line (3) to the sealing plate and remove the suction line from the sealing plate. A/C Underbody Lines - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1544 INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. 1. If removed, install the suction extension line (3) into the sealing plate (1) and install the nylon retaining clip (4). NOTE: Illustration shown with rear body cradle removed for clarity. 2. Position the underbody lines (3) and engage the underbody line brackets (1, 2, and 7) to the mounting studs located on the underbody (6). Rotate and tilt the underbody lines as necessary. Make sure the brackets are fully engaged to the studs. 3. Position the underbody line bracket (4) onto the mounting stud located near the center of the underbody and install the retaining nut (5). Tighten the nut securely. CAUTION: Use care not to damage the ABS wire lead or the brake line when repositioning the rear cradle. 4. Carefully raise the jack stand until the right side of the rear cradle is positioned to the body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1545 WARNING: Be sure to properly support the rear cradle when installing the right side retaining bolts. Failure to follow this warning may result in serious or fatal injury. 5. Install the bolts that secure the right side of the cradle to the body and remove the jack stand See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation. 6. Install the lower right rear shock retaining bolt See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over Installation. 7. Connect the rear ABS wire harness lead and bracket (4) to the right side of the body (3). 8. Position the right rear brake line (1) onto the two brackets (2 and 5) and install the two retaining bolts (6). Tighten the bolts securely. CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater tubes fittings when connecting the connections. Excessive force may damage or deform the tubes and or lines, causing an engine coolant leak. NOTE: Replacement of the rubber heater hose ends will be required if the rubber hoses were cut for removal. 9. Remove the tape or plugs from all the opened refrigerant line fittings and the rear expansion valve ports. 10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant extension line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 11. Connect the underbody refrigerant extension lines and sealing plate (2 and 6) to the rear A/C expansion valve. 12. Loosely install the nut (3) that secures the extension lines and sealing plate to the rear A/C expansion valve. 13. Connect the underbody refrigerant lines (7) to the underbody refrigerant extension lines and tighten the fitting nuts (1) to 23 Nm (17 ft. lbs.). 14. Tighten the nut that secures the extension lines and sealing plate to the rear A/C expansion valve to 11 Nm (97 in. lbs.). 15. Connect the underbody heater lines (5) to the rear heater core tubes located behind the right rear wheel housing and engage the spring type hose clamps (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1546 16. Position the underbody line shield (2) to the vehicle underbody and install the two nuts (3) and one screw (1). Tighten the fasteners securely. 17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 18. Connect the front A/C liquid and suction lines (7) to the underbody refrigerant lines (5). Tighten the fitting nuts (6) to 23 Nm (17 ft. lbs.). 19. Position the front A/C liquid and suction lines into the front underbody refrigerant line bracket (3) and engage the bracket retainer. NOTE: Replacement of the front heater hoses will be required if the hose ends were cut for removal. 20. Connect the front heater hoses (1) to the underbody heater lines (4) and engage the spring type hose clamps (2). 21. Install the exhaust heat shields as necessary. 22. Install the rear section of the exhaust system See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe Installation. 23. Lower the vehicle. 24. Reconnect the negative battery cable. 25. Fill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 26. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 27. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 28. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. A/C Underbody Extension Lines - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1547 NOTE: To prevent any contaminates from entering the rear heating-A/C system, make sure that the area around the underbody line connections is clean of any dirt or foreign residue prior to disconnecting the lines. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Disengage the underbody A/C extension lines (4) from the front underbody refrigerant line bracket (1). 5. Loosen the fitting nuts (3) that secure the underbody A/C extension lines to the underbody A/C liquid and suction lines (2). 6. Disconnect the underbody A/C extension lines from the underbody A/C liquid and suction lines and remove and discard the O-ring seals. 7. Install plugs in, or tape over the opened refrigerant line fittings. 8. Lower the vehicle. 9. Loosen the fitting nuts (3) that secure the underbody A/C extension lines (2) to the front A/C liquid and suction lines (1). 10. Disconnect the underbody A/C extension lines from the front A/C liquid and suction lines and remove and discard the O-ring seals. 11. Rotate and tilt the underbody A/C extension lines as necessary and remove the lines from the vehicle. 12. Install plugs in, or tape over the opened refrigerant line fittings. A/C Underbody Extension Lines - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1548 NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. 1. Remove the tape or plugs from the opened refrigerant extension line fittings. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the underbody A/C extension lines (2) into the engine compartment. Rotate and tilt the underbody A/C extension lines as necessary. 4. Connect the underbody A/C extension lines to the front A/C liquid and suction lines (1). Tighten the fitting nuts (3) to 23 Nm (17 ft. lbs.). 5. Raise and support the vehicle. 6. Remove the tape or plugs from the opened underbody refrigerant line fittings. 7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the underbody A/C extension lines (4) to the underbody A/C liquid and suction lines (2). Tighten the fitting nuts (3) to 23 Nm (17 ft. lbs.). 9. Position the underbody A/C extension lines into the front underbody refrigerant line bracket (1) and engage the bracket retainer. 10. Lower the vehicle. 11. Reconnect the negative battery cable. 12. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 13. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 14. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Testing and Inspection Power Steering Line/Hose: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Steering and Suspension/Steering/Testing and Inspection/Component Tests and General Diagnostics CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications/Mechanical Specifications/Steering/System Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications/Mechanical Specifications/Steering/System Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications/Mechanical Specifications/Steering/System Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal Power Steering Line/Hose: Service and Repair Power Steering Hose - Removal Pressure Hose 3.5L ENGINE NOTE: Before proceeding, See: Steering and Suspension/Steering/Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Raise and support the vehicle See: . 4. Unscrew the tube nut (3), then remove the pressure hose (4) at the steering gear. 5. Lower the vehicle. 6. Unscrew the tube nut (3), then remove the pressure hose (1) at the pump (4). 7. Remove the pressure hose routing clamp bolt (2) at the engine cylinder head. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1554 8. Accessing it through the area behind the powertrain control module (3), remove the routing clamp screw (2) securing the pressure hose (1) to the left side of the front suspension crossmember. 9. Remove the power steering pressure hose from the vehicle. Return Hose REMOVAL NOTE: Before proceeding, See: Steering and Suspension/Steering/Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the power steering fluid reservoir.See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal 3. Remove the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal 4. Raise and support the vehicle. See: 5. If equipped, remove the belly pan below the engine. 6. Remove the lower fascia valance. 7. Remove the return hose (1) at the return tube (2). If equipped with a screw-clamp, be sure to save the original clamp for reinstallation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1555 8. Remove the hose clamps (5) attaching the fluid return hoses (7) to the power steering fluid cooler line (4). Separate the return hoses from the cooler line. 9. Remove the return hose routing clamp screws (3) securing the return hose (7) to the frame rail. 10. Remove the return hose routing clamp screw (6) securing the return hose (7) to the frame rail. 11. Lower the vehicle. 12. Remove the return hose routing clamp screw (1) securing the return hose (7) to the body. 13. Remove the return hose from the vehicle. Supply Hose 3.5L ENGINE NOTE: Before proceeding, See: Steering and Suspension/Steering/Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the clamp (3) securing the supply hose (2) to the power steering pump supply fitting (4), then remove the hose from the supply fitting. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1556 3. Remove the mounting screws (1) securing the coolant recovery container (4) in place. 4. Lift the coolant recovery container as high as its connected hoses will allow, then remove the clip (6) securing the supply hose to the coolant recovery container's lower mounting point. 5. Remove the hose clamp (1) securing the supply hose (2) to the power steering fluid reservoir (7). Slide the hose off the end of the reservoir fitting and remove from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1557 Power Steering Line/Hose: Service and Repair Power Steering Hose - Installation Pressure Hose 3.5L ENGINE CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts, vehicle components and any unfriendly surface that can possibly damage the hoses. 1. Install the pressure hose into the engine compartment from above between the engine and the upper radiator hose. Then route the hose down the left side of the engine above the transmission, down to the steering gear. 2. Raise and support the vehicle See: . 3. Install the pressure hose tube (4) at the gear. Tighten the tube nut (3) to 32 Nm (24 ft. lbs.). 4. Lower the vehicle. 5. Accessing it through the area behind the powertrain control module (3), position the power steering hose (1) routing clamp at the left side of the front suspension crossmember. Install and tighten the routing clamp screw (2) to 14 Nm (10 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1558 6. Using a lint free towel, wipe clean the open power steering pressure hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid. 7. Install the pressure hose (1) at the power steering pump (4). Tighten the tube nut (3) to 32 Nm (24 ft. lbs.). 8. Position the pressure hose (1) routing clamp at the engine cylinder head. Install and tighten the routing clamp bolt (2) to 22 Nm (16 ft. lbs.). 9. Fill and bleed the power steering system See: Steering and Suspension/Steering/Service and Repair/Steering - Power Steering System Bleeding. 10. Check for leaks. Return Hose INSTALLATION 1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose routing clamp screw (1) securing the return hose (7) to the body. 3. Raise and support the vehicle. See: 4. Install the return hose routing clamp screw (6) securing the return hose (7) to the frame rail. Tighten the screw to 8 Nm (71 in. lbs.). 5. Install the screws (3) securing the return hose to the frame rail (2). Tighten the screws to 8 Nm (71 in. lbs.). 6. Install the return hose onto the cooler line (4) and install the hose clamps (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1559 7. Install the return hose (1) at the return tube (2) and install the clamp. If a screw-clamp is used, tighten it to 2.5 Nm (20 in. lbs.). 8. Install the lower fascia valance. 9. If equipped, install the belly pan below the engine. 10. Lower the vehicle. 11. Install the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation 12. Install the power steering fluid reservoir. See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation 13. Fill and bleed the power steering system. See: Steering and Suspension/Steering/Service and Repair/Steering - Power Steering System Bleeding 14. Check for leaks. Supply Hose 3.5L ENGINE 1. Slide hose clamps (1, 3) onto the ends of the power steering fluid supply hose (2) far enough to clear the fittings on the reservoir and pump once the hose is installed. 2. Place the pump end of the supply hose onto the pump supply fitting (4). Expand the hose clamp (3) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 3. Lift the coolant recovery container as high as its connected hoses will allow, then install the clip (6) in the mounting hole (5) securing the supply hose to the coolant recovery container's lower mounting point. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1560 4. Lower the coolant recovery container (4) to its mounted position and install the mounting screws (1). 5. Place the fluid reservoir end of the supply hose (2) onto the reservoir (7) supply fitting. Expand the hose clamp and slide it over the hose and fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 6. Fill and bleed the power steering system. See: Steering and Suspension/Steering/Service and Repair/Steering - Power Steering System Bleeding 7. Check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1566 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1567 Brake Fluid: Specifications Brake Master Cylinder .......................................................................................................................................... Mopar DOT 3, SAE J1703 or equivalent If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1568 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar(R) Brake Fluid or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1569 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1570 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECKING NOTE: Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. See: Specifications NOTE: Although there is a range, the preferred level is FULL. 1. Remove the cap. 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir as necessary. Do not overfill the system. 3. Install the cap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1575 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1580 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Single or Dual Zone Climate Control System ................................................................................................................................................. 9.8 qts. (9.3 L) Three-Zone Climate Control System ............................................................................................................................................................. 12 qts. (11.4 L) Includes heater and coolant recovery bottle filled to MAX level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1583 Coolant: Fluid Type Specifications Coolant ...................................... Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description - Engine Coolant Coolant: Description and Operation Description - Engine Coolant ENGINE COOLANT GAS ENGINES WARNING: Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of propylene glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol based coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description - Engine Coolant > Page 1586 Coolant: Description and Operation Operation COOLANT Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1587 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Check coolant concentration when any additional coolant is added to the system, or after a coolant drain, flush and refill. Use of a hydrometer or Refractometer Tool 8286, refractometer can be used to test coolant concentration. A hydrometer tests the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and the higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 tests the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufacturers use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and are not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1592 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1597 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1602 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1607 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1612 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 41TE/41AE Estimated Service Fill ....................................................................................................... ........................................................... 4.0 qts (3.8L) 41TE/41AE Overhaul Capacity with Torque Converter Empty ....................................................................................................................... 9.2 qts (8.7L) 62TE Estimated Service Fill ................................................................................................................ ............................................................. 5.5 qts (5.2L) 62TE Overhaul Capacity with Torque Converter Empty ................................................................................................................................. 9.0 qts (8.5L) Dry fill capacity depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1615 Fluid - A/T: Fluid Type Specifications ATF Fluid ..................................................................................................................................................... Mopar ATF +4 Automatic Transmission Fluid Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1616 Fluid - A/T: Description and Operation AUTOMATIC/MANUAL TRANSAXLE FLUID NOTE: All transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Mopar (R) ATF+4 (Automatic Transmission Fluid) is required in the automatic and T355/BG6 manual transaxles. Substitute fluids can induce torque converter clutch shudder, or premature geartrain failure. Mopar (R) ATF+4 (Automatic Transmission Fluid) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check FLUID LEVEL AND CONDITION CHECK FLUID LEVEL CHECK USING THE SCAN TOOL 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. NOTE: When inserting dipstick special tool 9336A, excess insertion force may cause the dipstick to slip past the stop on the bracket in the transmission oil pan. An approximate distance that the dipstick should be inserted into the fill tube is 424 mm (16.69 in.). 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336A into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. 6. Check transmission oil temperature using the appropriate scan tool. 7. The transmission Oil Dipstick 9336A has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the Transmission Fluid Temperature (TFT) as viewed with the scan too, and the Transmission Fluid Graph, determine if the transmission oil level Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1619 is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. MOPAR(R) ATF+4 (Automatic Transmission Fluid) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1620 Fluid - A/T: Service and Repair Fluid/Filter Service FLUID AND FILTER SERVICE FLUID/FILTER SERVICE (RECOMMENDED) NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled MOPAR(R) ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Remove nuts at the oil filter. 4. Install a new filter and nuts, tighten to 5 Nm (40 in. lbs.). 5. Install the fluid filter oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 6. Clean the oil pan and magnet. Reinstall pan using new MOPAR(R) Silicone Adhesive sealant. Tighten oil pan bolts to 6 Nm (50 in. lbs.). 7. Pour four Quarts of MOPAR(R) ATF+4 through the dipstick opening. 8. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 in.) below the lowest mark on the dipstick. 10. Recheck the fluid level after the transaxle has reached normal operating temperature 82° C (180°F). Refer to Fluid Level and Condition Check for the proper fluid fill procedure See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid Level and Condition Check. 11. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1625 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1630 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1635 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Page 1636 Fluid - Differential: Specifications Rear Drive Assembly (RDA) .......................................................................................................................... Mopar Gear Lubricant 75W-90 or equivalent Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Page 1637 Fluid - Differential: Service and Repair STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID CHANGE The drain plug (2) for the differential assembly is located in the bottom of the differential assembly case, toward the rear of the unit. The fill plug (3) for the differential assembly is located on the left side of the assembly case. The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. 1. Raise the vehicle on a hoist. 2. Position a drain pan under the differential drain plug. 3. Remove the drain plug and allow the fluid to drain into the pan. 4. Install the drain plug and torque to 35 Nm (26 ft. lbs.). 5. Re-position the drain pan under the differential fill plug. 6. Remove the differential fill plug. 7. Using a suction gun or equivalent, fill the differential assembly with 0.7 L (0.74 Quarts) of Mopar(R) Gear and Axle Lubricant (75W-90). 8. Install the fill plug and torque to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1642 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 1643 Fluid - Transfer Case: Specifications Power Transfer Unit (PTU) ............................................................................................................................ Mopar Gear Lubricant 75W-90 or equivalent Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 1644 Fluid - Transfer Case: Service and Repair PTU FLUID DRAIN/FILL 1. Raise vehicle on hoist. 2. Remove bolt (1) from lower part of PTU heat shield (2). 3. Using a long prybar remove the retaining clip (1) from the side of the PTU heat shield (2). NOTE: Position the PTU heat shield aside as necessary 4. Remove PTU drain plug (1). Drain fluid into suitable container. 5. Install drain plug (1) and torque to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 1645 6. A 10mm hex bit 7/8" long (1) and a ratcheting box angle wrench (2) will be required to remove the PTU fill plug. NOTE: Position the PTU heat shield aside as necessary 7. Using the ratcheting box angle wrench (1) and hex bit (3) remove the PTU fill plug (2). 8. Use a gear lube pump (1) to fill PTU with.8L (1.7 Pints.) of Mopar(R) 75W-90 Gear and Axle Lubricant. 9. Install fill plug and torque to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 1646 10. Reposition the PTU heat shield (2) to the side of the PTU, and install a new retaining clip (1). 11. Reposition the PTU heat shield (2) to the bottom of the PTU, and install bolt (1). Tighten to 12 Nm (105 in. lbs.). 12. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1651 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ............................................................. 5.2L (5.5 qts) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1654 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ...................................... API SAE Certified 10W-30 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1655 Engine Oil: Description and Operation ENGINE OIL WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. When service is required, Chrysler recommends that only Mopar(R) brand parts, lubricants and chemicals be used. Mopar(R) provides the best engineered products for servicing Chrysler vehicles. Only lubricants bearing designations defined by the following organization should be used. - Society of Automotive Engineers (SAE) - American Petroleum Institute (API) - National Lubricating Grease Institute (NLGI) - Association des Constructeurs Europeens d' Automobiles (European Automobile Manufacturers Association) (ACEA) API CERTIFICATION AND LICENSE SYMBOL Use an engine oil that is API Certified and Licensed to display the certification mark. MOPAR(R) provides engine oils that meet or exceed, Material Standard MS-6395 requirement. SAE VISCOSITY Engine oils are designed to improve low temperature starting and vehicle fuel economy. Refer to the engine oil filler cap for the preferred engine oil viscosity grade for each vehicle. SAE viscosity grades are used to specify the correct viscosity oil for an engine. Use only Multi-Viscosity oils. These are specified with a dual SAE viscosity grade which indicates the cold (5W) to hot (20, 30) temperature performance range of the oil. ACEA CATEGORIES For countries that use the ACEA European Oil Categories for service fill oils, use engine oils that meet the requirements of ACEA A1/B1, A2/B2, or A3/B3. CONTAINER IDENTIFICATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1656 The Engine Oil Certification Mark was developed and trademarked by the API to refer customers to those engine oils preferred by the automobile manufacturers. This symbol means that the oil has been certified and licensed by the American Petroleum Institute (API). This certification mark will only be found on the front of the oil containers. Those oils that do not display the "Mark" on the front of the container should not be used. Chrysler only recommends API Certified engine oils that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395. SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that are certified by the American Petroleum Institute (API) to display the "Certification Mark" and show SAE viscosity grade recommended for each vehicle. Follow the service schedule that describes your driving type. ENGINE OIL ADDITIVES/SUPPLEMENTS The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines and emission systems by: - Increasing the level of Phosphorus and Sulfur in the engine oil. The API Certified Engine Oils control the Phosphorus and Sulfur contents of the oil to levels that reduce the contamination effect on the vehicles emission control system. - Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. - Creating potential for an undesirable additive compatibility interaction in the engine crankcase. The engine oils contain a performance additive system carefully developed to optimize the oils performance in the engine. The addition of supplements may cause the oil to thicken prematurely, cause excessive deposit build-up and potentially shorten engine life. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil. CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1659 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. See: WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. TO CHANGE ENGINE OIL 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Open hood, remove engine oil fill cap (1). 4. Raise vehicle on hoist. 5. Place a suitable drain pan under crankcase drain. 6. Remove oil pan drain plug (1) from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (2). 8. Install drain plug (1) in crankcase. Tighten oil pan drain plug to 27 Nm (20 ft. lbs.). 9. Install new oil filter (2). 10. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1660 11. Fill crankcase with specified type and amount of engine oil. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Description and Operation 12. Install oil fill cap (1). 13. Start engine and inspect for leaks. 14. Turn engine off and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. When replacing oil filter, use a Mopar(R) filter or equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING above. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1665 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1666 Power Steering Fluid: Specifications Power Steering Fluid ............................................................................... Mopar Power Steering Fluid +4, Mopar ATF +4 Automatic Transmission Fluid. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1667 Power Steering Fluid: Description and Operation POWER STEERING FLUID The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid. Both Fluids have the same material standard specifications (MS-9602). Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. The power steering system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. See: Steering and Suspension/Steering/Service and Repair/Power Steering Fluid Level Checking Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1668 Power Steering Fluid: Service and Repair POWER STEERING FLUID LEVEL CHECKING WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from moving parts and to assure an accurate fluid level reading. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. NOTE: Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. The power steering fluid level can be viewed through the side of the power steering fluid reservoir. Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the MAX. line. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE CAPACITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1673 Refrigerant: Fluid Type Specifications Type...................................................................................................................................................... .........................................................................R-134a Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Refrigerant - Description Refrigerant: Description and Operation Refrigerant - Description A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a nontoxic, nonflammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Refrigerant - Description > Page 1676 Refrigerant: Description and Operation Refrigerant - Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the poly alkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: If equipped with the rear heating-A/C system, use a heat gun to heat the underbody lines to help remove any trapped refrigerant from the rear A/C system. When servicing the A/C system, a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 must be used (1). Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1679 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. Do not operate the engine with a vacuum on the A/C system. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1680 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system See: Heating and Air Conditioning/Specifications/Capacity Specifications. When charging the A/C system, a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 must be used (1). Per SAE standard J2788, refrigerant recovery stations must charge the system to an accuracy of 14 grams (0.5 oz.). Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. See the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 2. Connect a manifold gauge set or R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible serious or fatal injury. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1685 Refrigerant Oil: Fluid Type Specifications Type...................................................................................................................................................... ..................................................................ND-8 PAG Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description Refrigerant Oil: Description and Operation Refrigerant Oil - Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, poly alkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available and each contain a different additive package. Always use only the type of refrigerant oil recommended for the A/C compressor in the vehicle. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. The A/C compressors used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description > Page 1688 Refrigerant Oil: Description and Operation Refrigerant Oil - Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1689 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Drain the refrigerant oil from the A/C compressor using the procedures described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. CAUTION: ND-8 PAG refrigerant oil is used in the A/C system. Only refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C receiver/drier, A/C evaporator or A/C condenser is replaced. Refer to the Refrigerant Oil Capacities charts. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. Refer to the following COMPRESSOR OIL DRAIN PROCEDURE. REFRIGERANT OIL CAPACITIES COMPRESSOR OIL DRAIN PROCEDURE - DENSO 6SEU16 VARIABLE DISPLACEMENT CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 6SEU16 A/C compressor can only be drained using the procedure described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. If the Denso 6SEU16 A/C compressor is being replaced, some refrigerant oil must first be drained from the replacement A/C compressor. The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 50 milliliters (1.7 oz.) of refrigerant oil from the replacement 6SEU16 compressor. Use the following procedure to drain and measure refrigerant oil from the Denso 6SEU16 A/C compressor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1690 1. Place the replacement A/C compressor (2) on a workbench and remove the drain plug (1). CAUTION: The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 50 milliliters (1.7 oz.) of refrigerant oil from the new 6SEU16 compressor when replacing only the compressor. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be removed from the replacement A/C compressor (example: new 6SEU16 compressor and receiver/drier requires 80 ml. (2.7 oz.) of oil to be added to the system. 100 ml. (3.4 oz.) of oil is in replacement compressor. 100 ml. (3.4 oz.) minus 80 ml. (2.7 oz.) equals 20 ml. (0.7 oz.) oil to be drained from replacement compressor). 2. Position the replacement A/C compressor so that the refrigerant oil can drain out of the drain port into a suitable clean measured container. Hold the replacement A/C compressor in this position until the required amount of refrigerant oil is drained from the compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 3. Reinstall the drain plug. Tighten the drain plug securely. 4. Install the replacement A/C compressor onto the engine See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor - Installation. COMPRESSOR OIL DRAIN PROCEDURE - DENSO 10SR15 AND 10SR17 FIXED DISPLACEMENT CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1691 damage. The Denso 10SR15 and 10SR17 A/C compressors are filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the Denso 10SR15 and 10SR17 A/C compressors. 1. Position the original A/C compressor so that the refrigerant oil can drain out of the suction and discharge ports into a suitable clean measured container. Hold the original A/C compressor in this position until all of the refrigerant oil is drained from the compressor. 2. Drain all of the refrigerant oil from the replacement A/C compressor into a clean measured container. 3. Refill the replacement A/C compressor with the same amount of refrigerant oil that was drained out of the original compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, See: CAUTION: Before removing the master cylinder reservoir cap, thoroughly clean the cap and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. Pressure bleeding the brakes is recommended, although the brakes may be manually bled or pressure bled. Refer to the appropriate following procedure. PRESSURE BLEEDING PROCEDURE Follow the pressure bleeder manufacturer's instructions for use of the pressure bleeding equipment. 1. Install Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the master cylinder fluid reservoir. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 3. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 4. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 5. Repeat this procedure at all the remaining bleeder screws. 6. Check and adjust brake fluid level to the FULL mark on the reservoir. 7. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. MANUAL BLEEDING PROCEDURE NOTE: To bleed the brakes manually, the aid of a helper will be required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1696 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. IPB CALIPER BRAKE BLEEDING PROCEDURE NOTE: The following procedure is normally only necessary if a rear brake caliper has been removed and installed, or replaced. Perform the following procedure on each rear brake caliper as necessary. 1. Raise and support vehicle. See: 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1697 3. Remove the brake caliper lower guide pin bolt (1). 4. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 5. Remove the outboard pad (5) from the adapter bracket. 6. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 7. Slowly pump the brake pedal until the caliper fingers touch the outboard surface of the brake rotor. Release the pedal. 8. Remove the brake caliper lower guide pin bolt. 9. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 10. Reinstall the outboard pad in the adapter bracket. 11. Open the caliper bleeder screw at least one full turn. 12. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1698 e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 13. Close the bleeder screw. 14. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 15. Have a helper pump the brake pedal three or four times and hold it in the down position. 16. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 17. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 18. Repeat the previous three steps until all trapped air is removed. 19. Tighten the guide pin bolt to 35 Nm (26 ft. lbs.). 20. Repeat the above procedure on the opposite rear brake caliper as necessary. 21. Check brake pedal travel and feel. If pedal travel is still excessive or if the pedal feels excessively spongy, repeat the entire procedure as necessary. 22. Install the tire and wheel assembly See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts to 135 Nm (100 ft. lbs.). 23. Lower the vehicle. 24. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1699 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. See: 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder fluid reservoir to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Circuit Breaker 1 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Circuit Breaker 1 > Page 1705 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) Circuit Breaker: Diagrams Circuit Breaker 1 (In TIPM) Connector - (IN TIPM) CIRCUIT BREAKER 1 - (IN TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 1708 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 1709 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 1710 Circuit Breaker: Diagrams Power Seat Circuit Breaker (Seat) 2 Way Connector - (SEAT) 2 WAY CIRCUIT BREAKER-POWER SEAT - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module Fuse: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1715 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1716 The Totally Integrated Power Module (TIPM) is located in the engine compartment near the air cleaner assembly. This center contains fuses and relays. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1717 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1718 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1719 Fuse: Locations Fuse Locations/Types FUSES/TOTALLY INTEGRATED POWER MODULE (TIPM) TOTALLY INTEGRATED POWER MODULE (TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1720 The Totally Integrated Power Module (TIPM) is located in the engine compartment near the air cleaner assembly. This center contains fuses and relays. CAUTION: - When installing the power module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the TIPM, and possibly result in an electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Relays FUSE LOCATIONS AND TYPES Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1721 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1722 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 1723 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1724 Fuse: Application and ID Connector - (IN TIPM) CIRCUIT BREAKER 1 - (IN TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1725 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1726 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 1729 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Service and Repair > IOD Fuse - Removal Fuse: Service and Repair IOD Fuse - Removal REMOVAL NOTE: When removing or installing the Ignition Off Draw (IOD) fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Pull on IOD fuse (J13) holder until it reaches the first detent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Service and Repair > IOD Fuse - Removal > Page 1732 Fuse: Service and Repair IOD Fuse - Installation INSTALLATION 1. Push on IOD fuse until completely seated. 2. Install the cover to the Totally Integrated Power Module (TIPM). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1751 Fuse Block: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1752 Fuse Block: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Run Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Run Relay > Page 1760 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Run Relay > Page 1761 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way Relay Box: Diagrams Run Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 1764 Relay Box: Diagrams Run/Accessory Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/ACCESSORY - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 1765 Relay Box: Diagrams Run/Start Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/START - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Page 1766 Relay Box: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Page 1767 Relay Box: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 1773 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > EVIC Equipped Vehicles Oil Change Reminder Lamp: Service and Repair EVIC Equipped Vehicles Oil Change Required Your vehicle is equipped with an engine oil change indicator system. The Oil Change Required message will flash in the EVIC for approximately 5 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON position. To turn off the message temporarily, press and release the MENU button on the instrument cluster. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: 1. Turn the ignition switch to the ON position (Do not start the engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > EVIC Equipped Vehicles > Page 1776 Oil Change Reminder Lamp: Service and Repair Non-EVIC Equipped Vehicles Change Oil Message (Base and Mid Line Clusters) Your vehicle is equipped with an engine oil change indicator system. The CHANGE OIL message will flash in the instrument cluster odometer for approximately 12 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON position. To turn off the message temporarily, press and release the TRIP ODOMETER button on the instrument cluster. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: 1. Turn the ignition switch to the ON position (Do not start the engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair HOISTING Refer to Owner's Manual provided with vehicle for proper emergency jacking procedures. WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When the engine or rear suspension is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. Failure to follow these instructions may result in personal injury or death. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands. A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1787 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1788 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1791 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1792 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1793 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1794 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1801 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1802 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1805 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1806 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1807 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1808 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-002-10 > May > 10 > Wheels/Tire - Highway Speed Vibration/Shake Tires: Customer Interest Wheels/Tire - Highway Speed Vibration/Shake NUMBER: 22-002-10 GROUP: Wheels/Tires DATE: May O7, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-08, DATED APRIL 19, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF VEHICLE MODEL YEARS. SUBJECT: Vehicle Vibration / Shake At Highway Speed OVERVIEW: This bulletin provides information to diagnose vehicle vibration concerns. MODELS: 2009-**2010** (JC) Journey DISCUSSION: Tires used on the Journey models include nylon cap material as part of their construction. Tires that include Nylon can temporarily "flat spot" when vehicles are shipped by car hauler or rail and if vehicles are stored for an extended period. Immediately following delivery, some vehicles may exhibit a vibration / shake due to temporary tire flat-spotting. The vibration may be felt in the steering wheel and / or seat, and may be most noticeable at highway speeds, 60mph (96 kph). This may be misinterpreted as an out of balance tire. NOTE: Do not attempt to rebalance the wheel/tire assembly until the vehicle has been driven for an extended period (20 minutes or more) at highway speeds. If the tires are flat-spotted, the vehicle vibration will go away after the tires are warmed up, (normally 10 to 20 minutes of highway driving depending on outside temperatures). If highway driving doesn't resolve the vehicle vibration, follow the procedures found in DealerCONNECT > TechCONNECT > Group 22 - Tires and Wheels > Tire and Wheel Vibration. Replacing tires should only be done as a last resort after all appropriate wheel and tire diagnostics have been completed. U.S. dealers can contact the MOPAR tire program if assistance is needed with obtaining any tire. POLICY: Reimbursable within the provisions of the warranty. **TIME ALLOWANCE**: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-002-11 > Apr > 11 > Wheels/Tires - Alternative 19 Inch Tires Tires: All Technical Service Bulletins Wheels/Tires - Alternative 19 Inch Tires NUMBER: 22-002-11 GROUP: Tires and wheels DATE: April 02, 2011 SUBJECT: Alternative 19 Inch Tires OVERVIEW: This bulletin specifies alternative 19 tires that should be used if the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) is not available. MODELS: 2009-2010 (JC) Journey NOTE: This bulletin applies to vehicles sold in U.S. and Canada (sales code YAA and YAC) markets only. DISCUSSION: The following 19 tires can be used as aftermarket replacement tires for the 2009 and 2010 model year Dodge Journey in the event that the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) are not available. Approved Alternative Tires: NOTE: It is recommended to use these tires only as sets of four. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-002-10 > May > 10 > Wheels/Tire - Highway Speed Vibration/Shake Tires: All Technical Service Bulletins Wheels/Tire - Highway Speed Vibration/Shake NUMBER: 22-002-10 GROUP: Wheels/Tires DATE: May O7, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-08, DATED APRIL 19, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF VEHICLE MODEL YEARS. SUBJECT: Vehicle Vibration / Shake At Highway Speed OVERVIEW: This bulletin provides information to diagnose vehicle vibration concerns. MODELS: 2009-**2010** (JC) Journey DISCUSSION: Tires used on the Journey models include nylon cap material as part of their construction. Tires that include Nylon can temporarily "flat spot" when vehicles are shipped by car hauler or rail and if vehicles are stored for an extended period. Immediately following delivery, some vehicles may exhibit a vibration / shake due to temporary tire flat-spotting. The vibration may be felt in the steering wheel and / or seat, and may be most noticeable at highway speeds, 60mph (96 kph). This may be misinterpreted as an out of balance tire. NOTE: Do not attempt to rebalance the wheel/tire assembly until the vehicle has been driven for an extended period (20 minutes or more) at highway speeds. If the tires are flat-spotted, the vehicle vibration will go away after the tires are warmed up, (normally 10 to 20 minutes of highway driving depending on outside temperatures). If highway driving doesn't resolve the vehicle vibration, follow the procedures found in DealerCONNECT > TechCONNECT > Group 22 - Tires and Wheels > Tire and Wheel Vibration. Replacing tires should only be done as a last resort after all appropriate wheel and tire diagnostics have been completed. U.S. dealers can contact the MOPAR tire program if assistance is needed with obtaining any tire. POLICY: Reimbursable within the provisions of the warranty. **TIME ALLOWANCE**: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 22-002-11 > Apr > 11 > Wheels/Tires - Alternative 19 Inch Tires Tires: All Technical Service Bulletins Wheels/Tires - Alternative 19 Inch Tires NUMBER: 22-002-11 GROUP: Tires and wheels DATE: April 02, 2011 SUBJECT: Alternative 19 Inch Tires OVERVIEW: This bulletin specifies alternative 19 tires that should be used if the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) is not available. MODELS: 2009-2010 (JC) Journey NOTE: This bulletin applies to vehicles sold in U.S. and Canada (sales code YAA and YAC) markets only. DISCUSSION: The following 19 tires can be used as aftermarket replacement tires for the 2009 and 2010 model year Dodge Journey in the event that the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) are not available. Approved Alternative Tires: NOTE: It is recommended to use these tires only as sets of four. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1831 Tires: Specifications FASTENER TORQUE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires Tires: Description and Operation Tires TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval on Tire Rotation. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Tire type, size, load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the Tire Identification chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An All Season type tire will also have either M + S, M AND S, or M - S (indicating mud and snow traction) imprinted on the side wall. An Extra or Light Load marking "XL" or "LL" may also be listed on the sidewall. The absence of an "XL" or "LL" marking infers a standard load tire. TIRE IDENTIFICATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 1834 NOTE: * Height (2) ÷ Width (1) = Aspect Ratio. NOTE: ** Consult the tire manufacturer regarding any questions on tire specifications or capabilities. TIRE CHAINS Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 1835 Tires: Description and Operation Spare Tire SPARE TIRE A compact (temporary) spare tire and wheel assembly is standard equipment on this vehicle. A full-size spare is available on some models. Export vehicles are equipped with the TIREFIT tire repair kit as standard equipment in place of a spare tire. It is to be used to repair small punctures in the tire as necessary. A compact spare tire is optional. The compact spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the compact spare tire. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 1836 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. WARNING: In order to maintain the speed capability of the vehicle, replacement tires must have speed ratings equal to or higher than those fitted to the vehicle as original equipment. If tires with lower speed ratings are fitted, the vehicle's handling may be affected and the speed capability of the vehicle may be lowered to the maximum speed capability of the replacement tires. To avoid an accident resulting in severe or fatal injury, consult the tire manufacturer in regards to maximum speed ratings. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 1839 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators will appear as a 13 mm (1/2 in.) band (3). Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRE CLEANING Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire And Loading Information Label provided with the vehicle (usually on the driver's door opening (B-pillar) or rear shutface of driver's door). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: Over or Under inflated tires can affect vehicle handling. The tire can fail suddenly, resulting in loss of vehicle control. Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1842 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks (1). Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEED OPERATION Refer to the vehicle's Owners Manual Package. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1843 Tires: Removal and Replacement TIRE LEAK REPAIRING For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the five wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1848 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1849 Wheels: Specifications SPECIFICATIONS BASE WHEEL TORQUE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1850 Wheels: Description and Operation DESCRIPTION All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps (2). In case of air loss, these raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire forces the tire bead over these raised sections into place. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1851 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Chrysler LLC does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit (93 degrees Celsius). - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1852 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire AND Wheel Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: - Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel bearing grease ............................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The front wheel bearing and wheel hub of this vehicle are a one piece sealed unit or hub and bearing unit type assembly. The hub and bearing (1) is mounted to the knuckle using four mounting bolts (2) and to the axle half shaft using a retaining nut. The center of the hub and bearing is splined to match the outer joint of the axle half shaft. Each front hub and bearing has five wheel mounting studs on the hub flange for mounting the wheel to the vehicle. The wheel mounting studs are the only replaceable components of the hub and bearing. Otherwise, the hub and bearing is serviced as a complete assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 1858 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (1) is mounted to the rear knuckle. All vehicles have a magnetic encoder integrated into the rear hub and bearing for speed sense. The encoder works with the rear wheel speed sensor (2) to provide wheel speed signal. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the hub and bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 1861 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Steering and Suspension/Suspension/Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1864 5. Remove the four bolts (2) fastening the hub and bearing to the knuckle (3). 6. Slide the hub and bearing (1) off the half shaft and out of the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1865 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the hub and bearing (1) by sliding it over the half shaft and into the knuckle. 2. Install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 Nm (60 ft. lbs.). 3. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 4. Clean all foreign matter from the threads of the half shaft outer C/V joint. 5. Install the hub nut (1) on the end of the half shaft (2) and lightly tighten it. 6. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (1) to 132 Nm (97 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1866 7. Install the tire and wheel assembly (1) See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1867 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal ALL-WHEEL-DRIVE NOTE: Before proceeding, See: Steering and Suspension/Suspension/Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. This will also allow more room to access the hub and bearing mounting bolts in a later step. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1868 6. Remove two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle (3). 7. Remove the disc brake caliper and adapter bracket (2) as an assembly from the knuckle (3) and rotor. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 8. Remove any retaining clips, then slide the brake rotor (2) off the hub and bearing (1). CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 9. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 10. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1869 11. Remove the four bolts (1) securing the hub and bearing to the knuckle. 12. Remove the hub and bearing from the knuckle and half shaft (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1870 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation ALL-WHEEL-DRIVE 1. With the brake shield in place on the knuckle, slide the hub and bearing over the axle half shaft and position it on the knuckle. 2. Install the four bolts (1) securing the hub and bearing to the knuckle. Tighten the bolts to 105 Nm (77 ft. lbs.). CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 3. Pass the wheel speed sensor head (2) through the hole in the brake shield, then push it into the mounting hole in hub and bearing (1) and align the mounting screw hole. 4. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1871 5. Clean the rotor mounting face of the hub and bearing (1) to remove any dirt or corrosion. 6. Install the brake rotor (2) over the hub and bearing (1). CAUTION: If the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism. 7. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1872 8. Install the disc brake caliper and adapter bracket (2) over the knuckle and rotor as an assembly. 9. Install the two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle. Tighten the mounting bolts to 100 Nm (74 ft. lbs.). NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 10. Clean all foreign matter from the threads of the half shaft outer C/V joint. 11. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 12. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 13. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 14. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1873 15. Install tire and wheel assembly (1) See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Check the brake fluid level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal Wheel Cover: Service and Repair Wheel Cover - Removal REMOVAL 1. Raise and support the vehicle so that tire and wheel assembly clears ground level. See: CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. It is held on by the wheel mounting nuts. 2. Remove the five wheel mounting (lug) nuts (3) from the wheel studs. While removing the nuts, hold the wheel cover (2) in place so it doesn't fall off when the last nut is removed. 3. Remove the wheel cover (2) using care not to let the tire and wheel assembly (1) fall off the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal > Page 1878 Wheel Cover: Service and Repair Wheel Cover - Installation INSTALLATION WARNING: Installing wheels without good metal-to-metal contact with the mounting surface could cause loosening of the wheel mounting (lug) nuts. This could adversely affect the safety and handling of the vehicle. NOTE: Never use oil or grease on studs or wheel mounting (lug) nuts. 1. With the tire and wheel assembly (1) positioned on the wheel studs without the wheel mounting (lug) nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover over the studs. NOTE: Always use the original (OEM) style wheel mounting (lug) nuts. Do not use replacement parts of lesser quality or substitute design. 2. Install and lightly snug all five wheel mounting (lug) nuts (3) Do not tighten at this time. 3. Lower the vehicle. 4. Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of 135 Nm (100 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension Hub Nut................................................................................................................................................ .....................................................132 Nm (97 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 1884 Axle Nut: Specifications Rear Suspension Hub Nut................................................................................................................................................ ...................................................245 Nm (181 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut.................................................................................................................... ...................................................135 Nm (100 ft.lbs) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal Wheel Fastener: Service and Repair Wheel Stud - Removal Front REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 2. Install Remover 8677 (3) on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Rear REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove rear brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 1890 2. Install Remover (3), Special Tool 8677, on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 1891 Wheel Fastener: Service and Repair Wheel Stud - Installation Front INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation Rear INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 1892 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair JUMP STARTING WARNING: Do not jump start a frozen battery, personal injury can result. Do not jump start a vehicle when the battery fluid is below the top of lead plates. Do not allow jumper cable clamps to touch each other when connected to a booster source. Do not use open flame near battery. Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Refer to instructions provided with device being used. Failure to follow these instructions may result in personal injury or death. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. NOTE: For information on accessing the battery for service or replacement See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal TO JUMP START A DISABLED VEHICLE: WARNING: - Take care to avoid the radiator cooling fan whenever the hood is raised. It can start anytime the ignition switch is ON. You can be hurt by the fan. - Do not attempt to push or tow your vehicle to get it started. Vehicles equipped with an automatic transaxle cannot be started this way. Unburned fuel could enter the catalytic converter and once the engine has started, ignite and damage the converter and vehicle. If the vehicle has a discharged battery, booster cables may be used to obtain a start from another vehicle. This type of start can be dangerous if done improperly, so follow this procedure carefully. - Do not use a booster battery or any other booster source with an output that exceeds 12 Volts. WARNING: - Battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin, or clothing. Don't lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush contaminated area immediately with large quantities of water. - A battery generates hydrogen gas, which is flammable and explosive. Keep flame or spark away from the vent holes. NOTE: The battery is stored in a compartment that is located behind the left front fender and is accessible through the wheel well. Remote jump-start terminals are located in the engine compartment. 1. Wear eye protection and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. 2. When boosting from a battery in another vehicle, park that vehicle within booster cable reach, but without allowing the vehicles to touch. Set parking brake, place automatic transaxle in PARK, and turn ignition to LOCK for both vehicles. WARNING: Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result. 3. Turn off the heater, radio, and all unnecessary electrical loads. 4. Remove the protective cover (1) over the remote jump-start positive battery post (2) (+) in the engine compartment. Connect one end of the jumper Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 1896 cable to the positive battery post (2). Connect the other end of the same cable to the positive terminal of the booster battery. 5. Connect the other cable, first to the negative terminal of the booster battery and then to the engine ground (-) of the vehicle with the discharged battery (5). Make sure you have a good contact on the engine ground. 6. If the vehicle is equipped with Sentry Key Immobilizer, turn the ignition switch to the ON position for three seconds before moving the ignition switch to the START position. 7. Start the engine in the vehicle that has the booster battery, let the engine idle a few minutes, and then start the engine in the vehicle with the discharged battery. 8. When removing the jumper cables, reverse the sequence exactly. Be careful of the moving belts and fan. 9. Reinstall the protective cover over the remote jump-start positive battery post. WARNING: During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting jump-start. WARNING: Any procedure other than above could result in: - Personal injury caused by electrolyte squirting out the battery vent; - Personal injury or property damage due to battery explosion; Damage to charging system of booster vehicle or of immobilized vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico Towing Information: Service and Repair Trailer Towing - NAFTA, Puerto Rico SPECIFICATION - TOWING, Trailer - NAFTA, Puerto Rico you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer, carefully review this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The Gross Vehicle Weight Rating (GVWR) is the total allowable weight of your vehicle. This includes driver, passengers, cargo, and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The Gross Trailer Weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables, and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The Gross Combination Weight Rating (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 150 lbs (68 kg) allowance for the presence of a driver.) Gross Axle Weight Rating (GAWR) The Gross Axle Weight Rating (GAWR) is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. You could lose control of the vehicle and have an accident. Failure to follow these instructions may result in possible serious or fatal injury. Tongue Weight (TW) Tongue weight (TW) is the downward force exerted on the hitch ball by the trailer. In most cases, it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle. Frontal Area Frontal area is the maximum height and maximum width of the front of a trailer. Trailer Sway Control - Electronic For information on this system, See: Brakes and Traction Control/Description and Operation. Trailer Sway Control - Mechanical The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the vehicle. These kinds of hitches are the most popular on the market today and they are commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1901 Weight Distributing Hitch System A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction / hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. Trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier Tongue Weights (TW) and may be required depending on vehicle and trailer configuration / loading to comply with Gross Axle Weight Rating (GAWR) requirements. Improper Adjustment of Weight Distributing System WARNING: - An improperly adjusted weight distributing hitch system may reduce handling, stability, braking performance, and could result in an accident. - Weight distributing systems may not be compatible with surge brake couplers. Consult with your hitch and trailer manufacturer or a reputable recreational vehicle dealer for additional information. Failure to follow these instructions may result in possible serious or fatal injury. Trailer Hitch Classification Your vehicle may be factory equipped for safe towing of trailers weighing over 2,000 lbs (907 kg) with the optional Trailer Tow Prep Package. See your authorized dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition. All trailer hitches should be professionally installed on your vehicle. Trailer Towing Weights (Maximum Trailer Weight Ratings) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1902 The following chart provides the maximum trailer weight ratings towable for your given drivetrain. Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of the vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on your bumper or trailer hitch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1903 Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on your vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options or authorized dealer-installed options must be considered as part of the total load on your vehicle. Refer to the "Tire and Loading Information" placard for the maximum combined weight of occupants and cargo for your vehicle. Towing Requirements To promote proper break-in of your new vehicle drivetrain components the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 mi (805 km) of vehicle operation. Doing so may damage the vehicle. - During the first 500 mi (805 km) of trailer towing, limit the speed to 50 mph (80 km/h). WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make your trailer towing as safe as possible: Make certain that the load is secured in the trailer and that it will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. You could lose control of your vehicle and have an accident. Failure to follow these instructions may result in possible serious or fatal injury. - When hauling cargo or towing a trailer, do not overload your vehicle or trailer. Overloading can cause a loss of control, poor performance, or damage to brakes, axle, engine, transaxle, steering, suspension, chassis structure, or tires. - Safety chains must always be used between your vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transaxle in PARK. Always, block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized. (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight.) Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. - Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. Refer to "Tires-General Information" for information on tire pressures and for proper tire inflation procedures. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer. Refer to "Tires-General Information" for information on tread wear indicators and for the proper inspection procedure. - When replacing tires, See: Wheels and Tires/Tires/Description and Operation for information on replacement tires and for the proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (454 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 1,000 lbs (454 kg) loaded, it should have its own brakes, and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances. WARNING: Do not connect trailer brakes to your vehicle's hydraulic brake lines. It can overload your brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase your stopping distance. When towing, you should allow for additional space between your vehicle and the vehicle in front of you. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1904 Towing Requirements - Trailer Lights AND Wiring 4 - Pin Connector Whenever you pull a trailer, regardless of the trailer size, stoplights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4- and 7-pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicles wiring harness. The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations. 7- Pin Connector Towing Tips Before setting out on a trip, practice turning, stopping, and backing up the trailer in an area located away from heavy traffic. Towing Tips - Automatic Transaxle The DRIVE range can be selected when towing. However, if frequent shifting occurs while in this range, select the "3" range for 4-speed automatic or the "5" range for 6-speed automatic. NOTE: Using the "3" or "5" range while operating the vehicle under heavy operating conditions will improve performance and extend transaxle life by reducing excessive shifting and heat build up. This action will also provide better engine braking. If you REGULARLY tow a trailer for more than 45 minutes of continuous operation, then change the automatic transaxle fluid and filter according to the interval specified for "police, taxi, fleet, or frequent trailer towing" in the Maintenance Schedule. NOTE: Check the 4-speed automatic transaxle fluid level before towing. The 6-speed transaxle is sealed and the fluid level cannot be checked. See your authorized dealer for assistance. Towing Tips - Electronic Speed Control (If Equipped) - Don't use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage until you can get back to cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Towing Tips - Autostick (R) (If Equipped) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1905 - By using the Autostick(R) modes and selecting a specific gear range, frequent shifting can be avoided. The highest gear range should be selected that allows for adequate performance. For example, choose "4" if the desired speed can be maintained. Choose "3" or "2" if needed to maintain the desired speed. - Extended driving at high RPM should be avoided to prevent excess heat generation. A reduction in vehicle speed may be required to avoid extended driving at high RPM. Return to a higher gear range or vehicle speed when road conditions and RPM level allows. Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1906 Towing Information: Service and Repair Vehicle Towing TOWING, Vehicle WARNINGS AND PRECAUTIONS WARNING: Do not allow towing attachment devices to contact the fuel tank or lines, fuel leakage can result. Do not lift or tow vehicle by front or rear bumper, or bumper energy absorber units. Do not venture under a lifted vehicle if not supported properly on safety stands. Do not allow passengers to ride in a towed vehicle. Use a safety chain that is independent from the towing attachment device. Failure to follow these instructions may result in personal injury or death. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not attach towing device to front or rear suspension components. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a flat bed towing device or wheel lift is recommended. When using a wheel lift towing device, be sure the unlifted end of disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees. TOWING A DISABLED VEHICLE NUMBER: Without The Ignition Key Front Wheel Drive (FWD) Special care must be taken when the vehicle is towed with the ignition in the LOCK position. Flat bed towing is the preferred towing method. However, if a flat bed towing vehicle is not available, a wheel lift towing vehicle may be used. Furthermore, rear towing is not recommended with the front wheels on the ground, as transaxle damage can result. If rear towing is the only alternative, a front end dolly must be used. Proper towing equipment is necessary to prevent damage to the vehicle. All Wheel Drive (AWD) The vehicle must be transported on a flat bed truck. Towing This Vehicle Behind Another Vehicle (Flat Towing With The Key In The Ignition And All Four Wheels On The Ground) CAUTION: - If the vehicle being towed requires steering, the ignition switch must be in the ON position, not in the LOCK or ACC position. - Do not attempt to tow this vehicle from the front with sling type towing equipment. Damage to the front fascia will result. - Do not push or tow this vehicle with another vehicle as damage to the bumper fascia and transaxle may result. If you must use the accessories (wipers, defrosters, etc.) while being towed, the key must be in the ON position, not the ACC position. Make certain the transaxle remains in NEUTRAL. Front Wheel Drive (FWD) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1907 The vehicle may be towed under the following conditions: The shift lever must be in NEUTRAL, the distance to be traveled must not exceed 15 mi (25 km), and the towing speed must not exceed 25 mph (40 km/h). Exceeding these towing limits may cause a transaxle failure. If the transaxle is not operative, or if the vehicle is to be towed more than 15 mi (25 km), the vehicle must be transported either with a flat bed truck or with the front wheels off the ground. All Wheel Drive (AWD) The vehicle may be towed under the following conditions: The shift lever must be in NEUTRAL, the distance to be traveled must not exceed 15 mi (25 km), the towing speed must not exceed 25 mph (40 km/h), and both front and rear wheels must be on the ground. Exceeding these towing limits may cause a transaxle failure. If the transaxle is not operative, or if the vehicle is to be towed more than 15 mi (25 km), the vehicle must be transported on a flat bed truck. Towing This Vehicle Behind Another Vehicle With A Tow Dolly Front Wheel Drive (FWD) Rear towing is not recommended with the front wheels on the ground, as transaxle damage can result. If rear towing is the only alternative, a front end dolly must be used. Proper towing equipment is necessary to prevent damage to the vehicle. All Wheel Drive (AWD) CAUTION: The manufacturer does not recommend towing an All-Wheel Drive (AWD) on a tow dolly. Vehicle damage may occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 1908 Towing Information: Service and Repair Recreational Towing (Behind Motorhome, etc.) RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) Recreational Towing Chart CAUTION: ONLY vehicles equipped with a MANUAL TRANSAXLE may be recreationally towed (flat towed) at any legal highway speed, for any distance, if the MANUAL TRANSAXLE is in NEUTRAL and the ignition key is in the ACC position. CAUTION: - DO NOT FLAT TOW any vehicle equipped with an AUTOMATIC TRANSAXLE. Damage to the drivetrain will result. If these vehicles require towing, make sure all four wheels are off the ground. - Front or rear wheel lifts should not be used. Internal damage to the transaxle will occur if a front or rear wheel lift is used when recreational towing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair HOISTING Refer to Owner's Manual provided with vehicle for proper emergency jacking procedures. WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When the engine or rear suspension is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. Failure to follow these instructions may result in personal injury or death. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands. A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Ratio .............................................................................................................................. ............................................................................ 10:1 Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1917 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the TIPM. 5. Install a suitable compression test gauge into the number 1 spark plug hole in cylinder head. 6. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT SPROCKET Camshaft Sprocket Bolt-Right Side.........................................................................................................................102 + 1/4 Turn Nm (75 + 1/4 Turn ft.lbs) Camshaft Sprocket Bolt-Left Side...........................................................................................................................102 + 1/4 Turn Nm (75 + 1/4 Turn ft.lbs) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal CAMSHAFT SPROCKETS CAUTION: The 3.5L engine is NOT a free-wheeling design. Therefore, care should be taken not to rotate the camshafts or crankshaft with the timing belt removed. NOTE: The camshaft timing gears are keyed to the camshaft. 1. Perform fuel pressure release procedure. See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 2. Remove front timing belt cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 3. Position crankshaft sprocket to the TDC mark on the oil pump housing by turning crankshaft in the clockwise direction 4. Install a dial indicator in number 1 cylinder to check TDC of the piston. Rotate the crankshaft until the piston is at exactly TDC. 5. Remove camshaft retainer/thrust plate from rear of right cylinder head. 6. Remove the cylinder head covers. 7. Remove rocker arm assemblies. 8. Remove the timing belt tensioner and timing belt. 9. Loosen and remove the left camshaft gear retaining bolt and washer. The left bolt is 255 mm (10.0 in.) long. NOTE: The camshaft timing gears are keyed to the camshaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1924 10. Hold the left camshaft sprocket with 36 mm (1 7/16 in.) box end wrench. 11. Remove the left camshaft sprocket. CAUTION: The camshaft must be pushed rearward approximately 3 1/2 inches to remove the camshaft gear retaining bolt and gear. Care must be taken not to scratch or nick the camshaft or cylinder head journals when moving camshaft. 12. Loosen and remove the right camshaft gear retaining bolt and washer. The right bolt is 213 mm (8 3/8 in.) long. NOTE: The camshaft timing gears are keyed to the camshaft. 13. Hold the right camshaft sprocket with 36 mm (1 7/16 in.) box end wrench and loosen the camshaft bolt. 14. Using a floor jack, raise the right side of the engine enough to allow clearance to remove the right camshaft bolt and washer. 15. Remove the right camshaft sprocket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1925 Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation CAMSHAFT SPROCKETS CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up. CAUTION: The camshafts must be pushed back into the cylinder head after the camshaft sprockets and retaining bolts are positioned. Care must be taken not to scratch or nick the camshaft or cylinder head journals when moving the camshafts. 1. Install the camshaft sprockets onto the camshafts. Install NEW sprocket attaching bolts into place. The 255 mm (10 in.) bolt is installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is installed into the right camshaft. Do not tighten the bolts at this time, they will be tightened at a later step. Camshaft sprocket timing marks should be aligned with inner cover timing marks at both sprockets. 2. Install the camshaft thrust plates (1) and seals. Tighten the bolts (2) to 28 Nm (250 in. lbs.). 3. Install the timing belt starting first at the crankshaft sprocket, then to remaining sprockets in a counterclockwise direction. 4. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley. Camshaft sprocket timing marks (1) and crankshaft sprocket timing mark (3) should still be aligned with the inner cover marks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1926 NOTE: It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner. See Timing Belt Removal for tensioner compression procedure See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal . 5. Hold the tensioner pulley against the belt and install the reset (pinned) timing belt tensioner (2) into the housing. Tighten attaching bolts to 28 Nm (250 in. lbs.). 6. Remove tensioner retaining pin to allow the tensioner to extend to the pulley bracket. 7. Hold the right camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the right camshaft bolt to 102 Nm (75 ft. lbs.) +90° turn. 8. Hold the left camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the left camshaft bolts to 102 Nm (75 ft. lbs.) +90° turn. 9. Install the rocker arm assemblies and cylinder head covers See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Installation 10. Install the front timing belt cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 1927 Camshaft Gear/Sprocket: Service and Repair Crankshaft Sprockets - Installation CRANKSHAFT SPROCKET CAUTION: To ensure proper installation depth of crankshaft sprocket, Sprocket Installer 6641 must be used. 1. Install crankshaft sprocket using Special Tools 6641 and C-4685-C1. 2. Install timing belt, See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Camshaft - Description Camshaft: Description and Operation Camshaft - Description DESCRIPTION A single overhead camshaft per cylinder head provides valve actuation. The left camshaft accommodates a cam sensor pick-up wheel and is therefore longer. Each camshaft is supported by four bearing journals. A thrust plate attached to the rear of each cylinder head controls camshaft end play. Right and left camshaft driving sprockets support a timing mark, are keyed, and not interchangeable because of the cam sensor pick-up wheel on the left sprocket. Camshaft bearing lubrication is provided via a oil supply passage through each rocker shaft pedestal dowel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Camshaft - Description > Page 1932 Camshaft: Description and Operation Camshaft - Operation OPERATION The camshaft is driven by the crankshaft via drive sprockets and belt. As the crankshaft turns, the timing belt turns the camshaft. The camshaft lobes press the lifters which in turn open the valves at the correct time. The valve spring returns the valve to the closed state. The camshaft has precisely machined lobes to provide accurate valve timing and duration. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures INSPECTION 1. Inspect camshaft bearing journals for damage and binding. If journals are binding, check the cylinder head for damage. Also check cylinder head oil holes for clogging. 2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the rocker arms. 3. Measure the lobe actual wear and replace camshaft if out of limit. Standard value is 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010 in.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1935 Camshaft: Removal and Replacement Camshaft - Removal REMOVAL NOTE: Camshafts are removed from the rear of each cylinder head. CAUTION: Care must be taken not to nick or scratch the journals when removing the camshaft. 1. Remove the camshaft sprocket See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Removal. 2. Remove the rocker arm shaft assembly. See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm Disassembly 3. To remove the right camshaft, remove the EGR Valve assembly. 4. Remove the camshaft thrust plate (1) or (2). 5. Carefully remove the camshaft from the rear of the cylinder head. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1936 6. NOTE: It may be necessary to remove the Powertrain Control Module (PCM) in order to remove the camshaft from the right cylinder head. Camshaft - Installation INSTALLATION NOTE: Care must be taken not to scrape or nick the camshaft journals when installing the camshaft into position. 1. Lubricate camshaft bearing journals, camshaft lobes and camshaft seal with clean engine oil and install camshaft into cylinder head. 2. Install the camshaft sprocket.See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Installation 3. Install the camshaft thrust plate (1) or (2). Clean the mating surfaces and apply the appropriate sealer as necessary. Torque fasteners to 28 Nm (250 in. lbs.). 4. If necessary, install the EGR Valve assembly and Powertrain Control Module (PCM). 5. Install the rocker arm assembly.See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS Proper noise diagnosis is essential in locating the source of a NVH complaint. Locating a lash adjuster (tappet) type noise can sometimes be difficult. As a result, an initial misdiagnosis may occur. Refer to the following chart indicating possible lash adjuster (tappet) noise sources and possible sources that could lead to a misdiagnosis. Refer to Lash Adjuster (Tappet) Noise Chart for Possible Causes and Correction of a lash adjuster (tappet) type noise. LASH ADJUSTER (TAPPET) NOISE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1940 Lifter / Lash Adjuster: Service and Repair HYDRAULIC LASH ADJUSTER BLEEDING NOTE: Use this procedure to manually bleed aerated oil from the lash adjuster and remove sponginess. 1. Run the engine, bringing it to operating temperature in order to freshly pressurize and warm the valvetrain system oil supply. 2. Remove cylinder head cover(s). 3. Rotate engine until the rocker arm is positioned on the base circle of the cam (1). 4. For intake rocker arm positions:CAUTION: If probe tip breaks off within the lash adjuster, replace the affected rocker arm. a. Adjust the gauge pin of Release Probe 8351 (1) to extend approximately 20 mm (0.787 in.). Then, carefully insert the release probe gauge pin into the lash adjuster service access hole (2). b. Gently unseat lash adjuster's internal check ball (4). c. While the internal check ball is held unseated, press the rocker arm (3) into the valve tip (5), allowing the hydraulic lash adjuster (6) within the rocker arm to fully collapse. Hold fully collapsed position for at least one second, or longer. d. Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn refills the high pressure chamber with non-aerated oil. e. Remove Release Probe 8351 to allow check ball to seat. f. Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, then repeat procedure. g. If the spongy condition cannot be removed, replace effected rocker arm(s). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1941 5. For exhaust rocker arm positions:CAUTION: If probe tip breaks off within the lash adjuster, replace the affected rocker arm. a. Adjust the gauge pins of two Release Probes 8351 (1) to extend approximately 20 mm (0.787 in.). Then, using the two release probes, carefully insert gauge pins into the lash adjuster service access holes (2). b. Gently unseat BOTH lash adjuster's internal check balls (4) at the same time. c. While the internal check balls are held unseated, press the rocker arm (3) into the valve tip (5), allowing the hydraulic lash adjuster (6) within the rocker arm to fully collapse. Hold fully collapsed position for at least one second, or longer. d. Slowly release the rocker arm, thereby allowing the lash adjuster to extend, which in turn refills the high pressure chamber with non-aerated oil. e. Remove the two Release Probes 8351 to allow check balls to seat. f. Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, repeat procedure. g. If the spongy condition cannot be removed, replace effected rocker arm(s). 6. Install the cylinder head cover(s). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm - Description Rocker Arm Assembly: Description and Operation Rocker Arm - Description ROCKER ARM Rocker arms are made of light weight permanent mold aluminum alloy with a roller type follower operating against the camshaft. The valve actuating end of the rocker arms are machined to retain hydraulic lash adjusters, eliminating the need for manual valve lash adjustment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm - Description > Page 1946 Rocker Arm Assembly: Description and Operation Rocker Arm - Operation OPERATION The rocker arm is the pivot point between the camshaft lobe and the valve. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm - Description > Page 1947 Rocker Arm Assembly: Description and Operation Rocker Arm Shaft - Description ROCKER ARM SHAFTS The rocker arm shafts are tubular steel and supported by several forged aluminum alloy pedestals, which are fastened to the cylinder head. Four shafts are used, one for each intake and exhaust rocker arm bank on each cylinder head. The shafts are hollow to provide a duct for lubricating oil flow from the cylinder head to the valve mechanisms. One hollow dowel per pedestal is used to locate the pedestal to the cylinder head, orient the exhaust rocker shaft, and serve as a cam bearing oil feed passage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures INSPECTION The rocker arm shafts are hollow and are used as lubrication oil ducts. The rocker arm and shaft assembly on the right side of the engine has an oil passage hole from the cylinder head located at the third rocker shaft support pedestal. The rocker arm and shaft assembly on the left side of the engine has an oil passage hole from the cylinder head located at the second rocker shaft support pedestal. NOTE: To prevent air ingestion into lash adjusters, avoid turning rocker arm assembly upside down. CAUTION: Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjuster and plastic retainer. The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly. Check rocker arms for wear or damage: - Roller scuffing or wear - Shaft bore scuffing or wear - Swivel pad on lash adjuster missing or broken - Rocker arm showing signs of fatigue or cracking - Roller axle protruding from arm Replace assembly as necessary if any rocker arms shows signs of wear. CAUTION: Do not remove lash adjuster from rocker arm assembly. Damage to the adjuster and rocker arm will result. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1950 Rocker Arm Assembly: Removal and Replacement Valve Rocker Arm - Removal REMOVAL 1. Remove the cylinder head covers See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. CAUTION: DO NOT use a number stamp or a punch to mark the rocker arms. Damage to the rocker arms could occur. 2. Using a permanent ink or paint marker, identify the location and position on each rocker arm. 3. Remove the rocker arm assembly bolts in the sequence shown. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1951 4. Remove the rocker arm assembly (2). NOTE: To prevent air ingestion into the lash adjusters, avoid turning the rocker arm assembly upside down. CAUTION: Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjusters and/or plastic retainers. Valve Rocker Arm - Disassembly DISASSEMBLY CAUTION: DO NOT use a number stamp or a punch to mark the rocker arms. Damage to the rocker arms could occur. 1. Using a permanent ink or paint marker, identify the location and position on each rocker arm and remove the rocker arm and shaft assembly See: Valve Rocker Arm - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1952 2. Remove the dowel pins using a 4 mm screw, nut, spacer, and washer installed into the pin. Thread the screw into the pin, then loosen the nut on the screw. This will pull the dowel out of the shaft support. Do not reuse the dowel pins. NOTE: The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head. 3. Remove the rocker arms and pedestals in order. 4. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or heavily worn. 5. Check the shaft oil holes for clogging with a small wire, clean as required. Valve Rocker Arm - Assembly ASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1953 CAUTION: The rocker arm shafts are hollow and are used as lubrication oil passages. The rocker arm and shaft assembly on the RIGHT side of the engine has an oil passage hole from the cylinder head to the third rocker shaft support. The rocker arm shaft assembly on the LEFT side of the engine has an oil passage hole from the cylinder head to the second rocker shaft support. NOTE: A new fully assembled rocker arm and shaft assembly can be installed on either the right or left side of the engine. The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head. 1. Position the shafts with the notches (1) facing up. Install the rocker arms and pedestals onto the shafts. CAUTION: New dowel pins must be installed when reassembling. 2. Install the dowel pins (2). The dowel pins (2) pass through the pedestal (3) into the exhaust rocker shafts. Dowel pins (2) should be pressed in until they bottom-out against the rocker shaft in the pedestal (3). 3. Install the rocker arm and shafts assembly See: Valve Rocker Arm - Installation Valve Rocker Arm - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1954 NOTE: The rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation. 1. Rotate camshaft gears clockwise to where the number one cylinder intake valves would just start to open. The camshaft lobes are now in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it. NOTE: A new fully assembled rocker arm and shaft assembly can be installed on either the right or left side of the engine. The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head. 2. Install the rocker arm and shaft assembly making sure that the identification marks (1) face toward the front of engine for left head and toward the rear of the engine for right head. 3. Tighten the rocker arm/shaft assembly bolts in the sequence shown to 31 Nm (275 in. lbs.). 4. Install the cylinder head covers See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING ROD BEARING Journal Diameter.................................................................................................................................. ...........................57.982-58.002 mm (2.282-2.283 in.) Bearing Diametrical Clearance....................... ................................................................................................................0.024-0.054 mm (0.0009-0.0021 in.) Bearing Clearance (Wear Limit)............................................................................ ...............................................................................0.062 mm (0.0024 in.) Out-of-Round (MAX)......... .............................................................................................................................................................. .....0.007 mm (0.0003 in.) Journal Diametrical Taper (MAX)................................................................ ......................................................................................0.006 mm (0.00025 in.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1959 Connecting Rod Bearing: Service and Repair CONNECTING RODS AND BEARINGS CONNECTING ROD BEARINGS The bearing caps are not interchangeable and should be marked at removal to insure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Fit all rods on one bank until complete. Limits of taper or out-of-round on any crankshaft journals should be held to specification limits. Bearings are available in 0.007 mm oversize (0.0003 in oversize), standard, 0.007 mm (0.0003 in) undersize 0.025 mm (0.001 in) undersize, and 0.254mm (0.010 in undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. 1. For measuring main bearing clearance and connecting rod bearing clearance use Plastigauge. For more information on using Plastigauge See: Service and Repair/Procedures/Measuring Bearing Clearance Using Plastigage. Refer to Engine Specifications for bearing clearance specifications See: Specifications/Engine - Specifications. SELECT FIT ROD BEARINGS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1960 1. Connecting rod bearings use select fit to achieve improved clearance control. On a new engine, the crankshaft journal is gaged to use a specific bearing size. The grade is indicated on the #9 counterweight (2) of the crankshaft and listed from left to right with the recommended size. SELECT FIT ROD BEARING GRADES How to Determine Rod Bearing Class This example shows how to determine the bearing class needed for each rod bearing, assuming that a new crankshaft is being installed in a new or existing engine block. If the code 'B' 'A' 'B' 'B' 'B' 'C' is stamped on the #9 counterweight of the crankshaft (3), then rod #1 would require Class 2 bearings, rod #2 would require Class 1 bearings, rod #3 would require Class 2 bearings, rod #4 would require Class 2 bearings, rod #5 would require Class 2 bearings, and rod #6 would require Class 3 bearings. EXAMPLE CONNECTING ROD BOLTS NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1961 1. Examine connecting rod bolts for stretching. Stretching can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced. 2. Before installing the bolts the threads should be cleaned and inspected. 3. Install clean bolts finger tight. Then alternately torque each bolt to assemble the cap properly. 4. Tighten the connecting rod cap bolts to specification. See: Specifications/Engine - Specifications CONNECTING ROD SIDE CLEARANCE 1. Mount a dial indicator to a stationary point on engine. Locate probe perpendicular to and resting against the connecting rod cap being checked. Move connecting rod all the way to rear of its travel (toward flywheel end of crank). Zero the dial indicator. Move connecting rod forward of to limit of travel (toward pulley end of crank) and read the dial indicator. Compare measurement to specification listed in engine specifications See: Specifications/Engine - Specifications. Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING ROD Journal Diameter.................................................................................................................................. ...........................57.982-58.002 mm (2.282-2.283 in.) Journal Out-of-Round (MAX).......................... .....................................................................................................................................0.007 mm (0.0003 in.) journal Diametrical Taper (MAX)....................................................................................... ................................................................0.006 mm (0.00025 in.) Connecting Rod Cap-Bolts......................................................................................................................................27 + 1/4 Turn Nm (20 + 1/4 Turn ft.lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1965 Connecting Rod: Description and Operation DESCRIPTION The pistons are made of a high strength aluminum alloy. Top land height has been decreased to reduce emissions. Piston skirts are coated with a solid lubricant for scuff resistance. Connecting rod is forged steel with a fractured connecting rod cap design. The connecting rod is also equipped with a squirt hole and attaches to the piston with a full floating pin retained by lock rings. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures FITTING PISTONS The pistons are machined to two different weight specifications and matched to rods based on weight. All piston and rod assemblies weigh the same to maintain engine balance. Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line See: Specifications/Engine - Specifications. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1968 Connecting Rod: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Remove the cylinder heads See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal 2. Remove the oil pan. See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. 4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe (1). 5. Remove connecting rod cap. Install protectors on connecting rod. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. Piston and Connecting Rod - Installation INSTALLATION 1. Install the piston rings. See: Piston Ring/Service and Repair/Removal and Replacement/Piston Ring(s) - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1969 NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down(1 and 2), the bolts must be replaced. 2. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced. 3. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1970 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. Ensure position of rings does not change during this operation. 5. Install connecting rod bolt protectors on rod bolts. 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank. 7. The arrow (1) on top of piston must be pointing toward front of engine and oil squirt hole on connecting rod faces the major thrust (right) side of the cylinder bore. 8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 9. Install rod caps. Install cleaned and inspected connecting rod bolts and tighten to 27 Nm (20 ft. lbs.) Plus 1/4 turn. 10. Install the cylinder head(s) See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation 11. Install the oil pan. See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications MAIN BEARING Main Bearing Diametrical Clearance.................................................................................................... ..........................0.032-0.062 mm (0.0013-0.0024 in.) Bearing Clearance (Wear Limit)....................... ....................................................................................................................................0.070 mm (0.0027 in.) Crankshaft DIA Out-of-Round (MAX)...................................................................................................................... ..............................................0.007 mm (0.0003 in.) Diametrical Taper (MAX).................................... ...............................................................................................................................0.006 mm (0.00025 in.) End Play.......................................................................................................................... ....................................................0.048-0.260 mm (0.002-0.010 in.) End Play (MAX)......................... ............................................................................................................................................................0 .330 mm (0.013 in.) Crankshaft Main Bearing Cap Inner Main Cap Bolts...............................................................................................................................................20 + 1/4 Turn Nm (15 + 1/4 Turn ft.lbs.) Outer Main Cap Bolts...............................................................................................................................................27 + 1/4 Turn Nm (20 + 1/4 Turn ft.lbs.) Tie Bolts (Horizontal)................................................................. ................................................................................................................28 Nm (250 in.lbs) NOTE: The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures Crankshaft Main Bearing: Procedures CRANKSHAFT MAIN BEARING FITTING The main bearings use a "select fit" system to achieve proper oil clearances between the bearings and the crankshaft. When main bearings are being selected for a new crankshaft, the block and crankshaft grade identification marks must be used to identify the correct main bearings to use. The cylinder block main bearing bore grade codes (1) are located on the left side front of the engine block, just below the cylinder head mounting surface. These grade marks (1, 2, 3, or 4) are read left to right, corresponding to main bearing bore 1, 2, 3, or 4. The grade marks for the crankshaft are located on the rearmost crankshaft counter weight. The crankshaft journal grade marks (A, B, or C) are read left to right, corresponding with journal number 1, 2, 3, 4. For an example, if the main bore grade on the side of the engine block is 3 and the journal grade on the #9 counterweight of the crankshaft is B, the proper select fit bearing would be a (2) +0.003 mm (+0.0001 in.). Refer to the EXAMPLE CRANKSHAFT MAIN BEARING SELECTION DATA for a more detailed example of how to properly select the main bearings. NOTE: Service main bearings have a number from (1-5) marked in ink on the bearing surface. For verification, refer to the MAIN BEARING SELECTION CHART for number to size identification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 1976 The upper main bearing (2) has an oil feed hole and a center groove to allow lubrication of the main journal and must be properly positioned in the block. MAIN BEARING SELECTION CHART How to Determine Crankshaft Main Bearing Class Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 1977 This example shows how to determine the bearing class needed for each crankshaft main journal, assuming that a new crankshaft is being installed in a new or existing engine block. If the code 'B' 'B' 'A' 'C' is stamped on the #9 counterweight of the crankshaft (3), and the code '1' '2' '2' '3' is stamped on the side of the engine block (1), then main #1 would require Class 4 bearings, main #2 would require Class 3 bearings, main #3 would require Class 2 bearings, and main #4 would require Class 3 bearings. EXAMPLE CRANKSHAFT MAIN BEARING SELECTION DATA Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 1978 Crankshaft Main Bearing: Removal and Replacement Crankshaft Main Bearing(s) - Removal REMOVAL Bearing caps are not interchangeable and are marked to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. 1. Remove oil pan. See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 2. Remove oil pick-up tube and windage tray. 3. Identify bearing caps before removal. 4. Remove bearing caps one at a time. Remove upper half of bearing (2 and 4) by inserting Special Main Bearing Tool C-3059A (1 and 3) into the oil hole of crankshaft. 5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. Crankshaft Main Bearing(s) - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 1979 Bearing caps are not interchangeable and are marked to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. CAUTION: Main bearings are select fit. See: Procedures NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1. Lubricate main bearing with clean engine oil. 2. Start bearing in place, and insert Main Bearing Tool C-3059A into oil hole of crankshaft. 3. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059A. NOTE: Lubricate main bearing cap bolts with engine oil before installation. 4. Lubricate and install lower bearing half and main cap Tighten bolts finger tight. 5. For installing thrust washers (1) at the No. 2 main bearing location, use the following procedure: a. Move crankshaft forward to limit of travel. Lubricate and install the front thrust washer by rolling the washer (1) onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. b. Move crankshaft rearward to limit of travel. Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts. 6. Install each main bearing cap and tighten inner bolts finger tight. 7. Tighten inner main bearing cap bolts to 20 Nm + 1/4 turn (15 ft. lbs. + 1/4 turn). 8. Measure crankshaft end play. See: Crankshaft/Service and Repair/Procedures 9. Install windage tray. Lubricate bolts with engine oil and tighten to 27 Nm + 1/4 turn (20 ft. lbs. + 1/4 turn). 10. Install the main cap tie (horizontal) bolts and tighten to 28 Nm (250 in. lbs.). 11. Install oil pick-up tube. 12. Install oil pan. See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation 13. Fill engine crankcase with proper oil to correct level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Removal REMOVAL 1. Remove the engine oil panSee: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan Removal. 2. Lower the weight of the engine back onto the engine mounts. NOTE: Before separating the transmission from the engine, use an appropriate support fixture or lifting device to support the weight of the engine. 3. Remove transmission from vehicle. 4. Remove the flex plate. 5. Remove the rear crankshaft oil seal retainer bolts. 6. Remove the crankshaft oil seal and clean all mating surfaces. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 1984 Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Installation INSTALLATION CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), clean surface using 400 grit sand paper to prevent seal damage during installation. Make sure the rear crankshaft oil seal surface is clean and free of any abrasive materials. NOTE: The rear crankshaft oil seal and retainer are an assembly. DO NOT separate the seal protector from the rear crankshaft oil seal before installation on engine. Damage to the seal lip will occur if the seal protector is removed and installed prior to installation on engine. 1. Apply engine oil to crankshaft seal surface. 2. If the seal protector (1) is missing or was accidentally dislodged, go to 3. Otherwise, carefully position the oil seal retainer assembly (3), and seal protector (1) on crankshaft and push firmly into place on engine block (during this step, the seal protector will be pushed from the rear oil seal assembly as a result of installing the rear oil seal). Hand tighten the rear oil seal fasteners, and go to 4. NOTE: The seal lip (2) must always uniformly curl inward toward the engine on the crankshaft (1). CAUTION: If for any reason the installation sleeve is missing or dislodged from rear crankshaft oil seal prior to installation, the following Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 1985 procedure must be performed. 3. Using the chamfered seal guide from Special Tool 6926, insert the tapered end (1) into the transmission side of the rear crankshaft oil seal assembly (2), and push the seal guide through the seal assembly. This will ensure the seal lip is positioned toward the engine when the seal assembly is installed. When the seal lip is correctly positioned, go to 2. NOTE: The following steps must be performed to prevent oil leaks at sealing joints. 4. Attach Special Tools 8225 (1) to pan rail using the oil pan fasteners . NOTE: Special Tools 8225 (1), are use to assist with the fit of the flush mount rear main seal retainer. The notch on tool should be located away the seal retainer. 5. While applying firm pressure to the seal retainer against Special Tools 8225 (1), tighten seal retainer screws to 12 Nm (105 in. lbs.). 6. Remove special tool #8225 (1). NOTE: Make sure that the seal flange is flush with the block oil pan sealing surface. 7. Install oil pan. Tighten the 6mm fasteners to 12 Nm (105 in.lbs.) and the 8mm fasteners to 28 Nm (250 in.lbs.). 8. Install the flex plate and transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications CRANKSHAFT MAIN BEARING JOURNALS CONNECTING ROD JOURNALS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Description and Operation > Crankshaft - Description Crankshaft: Description and Operation Crankshaft - Description DESCRIPTION The crankshaft is constructed of a forged micro alloy steel. A six throw, nine counterweight crankshaft is supported by four select fit main bearings with number two serving as the thrust washer location. The six separate connecting rod throws are an even-firing design which reduces torque fluctuations while a torsional vibration damper is used to control torsion caused vibration of the crankshaft. Rubber lipped seals are used at front and rear. The front seal is retained in the oil pump case and the rear seal is retained in a block-mounted housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Description and Operation > Crankshaft - Description > Page 1991 Crankshaft: Description and Operation Crankshaft - Operation OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures Crankshaft - Inspection INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper on any crankshaft journals should be held to 0.015 mm (0.0006 in.). Limits for journal roundness should be 0.010 mm (0.0004 in.). Journal grinding should not exceed 0.254 mm (0.010 in.) under the standard journal diameter. DO NOT grind thrust faces of Number 2 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With a forged steel crankshaft it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Measuring Crankshaft End Play MEASURING CRANKSHAFT END PLAY 1. Mount a dial indicator to front of engine with the locating probe on nose of crankshaft. 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. Crankshaft end play must be within specification See: Specifications/Engine Specifications. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1994 Crankshaft: Removal and Replacement Crankshaft - Removal REMOVAL 1. Remove engine from vehicle See: Service and Repair/Removal and Replacement/Engine Removal. 2. Remove oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan Removal. 3. Remove oil pickup tube (1) and windage tray (3). 4. Remove front timing belt cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 5. Remove timing belt and tensioner See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal. 6. Remove crankshaft sprocket See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Removal. 7. Tap dowel pin out of crankshaft. 8. Remove oil pump assembly See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1995 9. Remove crankshaft rear oil seal retainer (1). NOTE: Do not use a metal stamp to mark the bearing caps. Do use a scribe or paint mark. 10. Identify rod bearing caps before removal. Also scribe a location reference mark from the #2 main bearing cap to the engine block to use as a guide during reassembly. 11. Remove connecting rod bearing caps. Connecting rod bearing caps are not interchangeable and should be paint marked or scribed before removal to insure correct assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1996 12. Remove main bearing caps (1). Main bearing caps are not interchangeable and are marked to insure correct assembly and location. 13. Remove crankshaft (4) from cylinder block (7). NOTE: Before installing crankshaft, refer to fitting of main bearings and installation of connecting rod bearings See: Crankshaft Main Bearing/Service and Repair/Procedures and See: Connecting Rod Bearing/Service and Repair . Crankshaft - Installation INSTALLATION CAUTION: Main bearings are select fit See: Crankshaft Main Bearing/Service and Repair/Procedures for proper bearing size selection. 1. Install crankshaft upper main bearings in cylinder block. Ensure oil holes in bearings line up with oil holes in cylinder block See: Crankshaft Main Bearing/Service and Repair/Procedures. 2. Install the crankshaft to cylinder block. 3. Move crankshaft forward to limit of travel. Lubricate and install the front thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. 4. Move crankshaft rearward to limit of travel. Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1997 5. Install lower main bearings (3) into main bearing caps (1). 6. Lubricate lower main bearings (3) with clean engine oil. NOTE: Lubricate main bearing cap inner bolts (2) with engine oil before installation. 7. Install each main cap (1) and tighten inner bolts (2) finger tight. Align the location reference mark scribed on the #2 main bearing cap during disassembly. CAUTION: The #2 main bearing cap must be centered over the inner bolt holes located on the block. Failure to center the bearing cap can result in contact with the crankshaft counterweights and thrust bearing failure. 8. Verify that the #2 main bearing cap is properly centered over the inner bolt holes located in the block. Tighten main bearing cap inner bolts to 20 Nm (15 ft. lbs.). 9. Move crankshaft (1) forward to limit of travel so that crankshaft thrust face (2) is tight against thrust bearing. 10. Verify that a 0.25 mm (0.010 inch) shim or feeler gage will fit between the #2 main cap (rear face) and the crankshaft thrust face. Slide the gage side-to-side all of the way across the cap making sure that the clearance at all areas exceeds 0.25 mm (0.010 inch). The feeler gage should slide all the way down to the #2 main journal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1998 11. Move crankshaft (1) rearward to limit of travel so that crankshaft thrust face (2) is tight against thrust bearing. 12. Verify that a 0.25 mm (0.010 inch) shim or feeler gage will fit between the #2 main cap (front face) and the crankshaft thrust face. Slide the gage side-to-side all of the way across the cap making sure that the clearance at all areas exceeds 0.25 mm (0.010 inch). The feeler gage should slide all the way down to the #2 main journal. 13. A properly centered #2 main bearing cap has a minimum of 0.25 mm (0.010 inch) clearance in both the forward and rearward crankshaft positions. If measured clearance is less than 0.25 mm (0.010 inch), loosen and reposition #2 main bearing cap until this minimum clearance can be verified by repeating this procedure. 14. Following verification of proper #2 bearing cap centering, finish tightening the main bearing cap inner bolts an additional 90° turn. 15. Measure crankshaft end play See: Procedures. 16. Install connecting rods and measure side clearance See: Connecting Rod Bearing/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1999 NOTE: The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts. 17. Install windage tray (3). Lubricate bolts with engine oil. Finger tighten all bolts first, then tighten to 28 Nm + 90° turn (20 ft. lbs. + 90° turn) beginning with the inside bolts tightening outward. 18. Install oil pickup tube (1) and tighten bolt to 28 Nm (20 ft. lbs.). 19. Install the main cap tie (horizontal) bolts and tighten to 28 Nm (20 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 2000 20. Install rear crankshaft oil seal retainer and oil seal See: Crankshaft Seal Retainer/Service and Repair/Crankshaft Rear Oil Seal Retainer Installation. 21. Install oil pump assembly See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 22. Install dowel pin in crankshaft. 23. Install crankshaft sprocket See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Installation. 24. Install timing belt and tensioner See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Installation. 25. Install front timing belt cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation. 26. Install oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation. 27. Install engine assembly See: Service and Repair/Removal and Replacement/Engine - Installation. 28. Fill engine crankcase with proper amount of oil. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation OPERATION When power is applied (110 volt A.C.) to the block heater, the heating element transfers heat through the aluminum engine block and into the coolant without directly penetrating the cooling system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 2004 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER TESTING If unit does not operate, test power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or 12-volt test light. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal 3.5L 1. Raise vehicle on hoist. 2. Detach power cord plug from heater. 3. Remove block heater attaching screw located below heater terminals. 4. Remove block heater from cylinder block. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 2007 Engine Block Heater: Service and Repair Engine Block Heater - Installation 3.5L 1. Thoroughly clean cylinder block heater cavity. 2. Insert heater assembly into block such that mounting hole is located below heater terminals. 3. Install mounting screw and tighten to 12 Nm (105 in. lb.). CAUTION: To prevent damage, the power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds. 4. Attach power cord to heater. 5. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications CRANKSHAFT PULLEY Crankshaft Damper-Bolt....................................................................................................................... ........................................................95 Nm (70 ft.lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Removal REMOVAL 1. Disconnect negative battery cable. 2. Raise vehicle on hoist. 3. Remove the right engine mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator Removal. 4. Remove the right front wheel and accessory drive belt splash shield. 5. Remove accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 6. Suitably support the engine. 7. Remove the lower crossmember. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal 8. Low the engine. 9. Remove vibration damper bolt. 10. Use Special Tool 1023 puller (1) , and insert 9020 (2), remove crankshaft damper. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal > Page 2013 Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Installation INSTALLATION 1. Install crankshaft damper using Special Tools C-4685-C1 (5.9 in.) Bolt (2), with Nut and Thrust Bearing from 6792, and 6792-1 (1) Installer. 2. Install vibration damper bolt. Torque bolt to 95 Nm (70 ft. lbs.). 3. Install the lower crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation. 4. Install accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 5. Install the accessory drive belt splash shield and right front wheel. 6. Lower vehicle. 7. Install the right engine mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator Installation. 8. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications PISTONS PISTONS PISTON PINS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2017 Piston: Description and Operation DESCRIPTION The pistons are made of a high strength aluminum alloy. Top land height has been decreased to reduce emissions. Piston skirts are coated with a solid lubricant for scuff resistance. Connecting rod is forged steel with a fractured connecting rod cap design. The connecting rod is also equipped with a squirt hole and attaches to the piston with a full floating pin retained by lock rings. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures FITTING PISTONS The pistons are machined to two different weight specifications and matched to rods based on weight. All piston and rod assemblies weigh the same to maintain engine balance. Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line See: Specifications/Engine - Specifications. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2020 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Remove the cylinder heads See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal 2. Remove the oil pan. See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. 4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe (1). 5. Remove connecting rod cap. Install protectors on connecting rod. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. Piston and Connecting Rod - Installation INSTALLATION 1. Install the piston rings. See: Piston Ring/Service and Repair/Removal and Replacement/Piston Ring(s) - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2021 NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down(1 and 2), the bolts must be replaced. 2. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced. 3. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2022 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. Ensure position of rings does not change during this operation. 5. Install connecting rod bolt protectors on rod bolts. 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank. 7. The arrow (1) on top of piston must be pointing toward front of engine and oil squirt hole on connecting rod faces the major thrust (right) side of the cylinder bore. 8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 9. Install rod caps. Install cleaned and inspected connecting rod bolts and tighten to 27 Nm (20 ft. lbs.) Plus 1/4 turn. 10. Install the cylinder head(s) See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation 11. Install the oil pan. See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RINGS PISTON RING SIDE CLEARANCE PISTON RING WIDTH Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2026 Piston Ring: Description and Operation DESCRIPTION The piston rings include a moly-filled top ring with a symmetrical barrel face. The intermediate piston ring (2 and 3) is of the Micro-Napier design. The Micro-Napier design has a reduced "hook" on the running face, removes the need for chroming and improves oil economy. The oil control package consists of two steel rails and an expander spacer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures Piston Ring: Procedures PISTON RING FITTING 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore. Check gap with feeler gauge (1). For clearance specifications, See: Specifications/Engine - Specifications. 2. Check piston ring to groove clearance (1). For clearance specifications, See: Specifications/Engine - Specifications. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures > Page 2029 Piston Ring: Removal and Replacement Piston Ring(s) - Removal REMOVAL 1. Remove piston and connecting rod. See: Connecting Rod/Service and Repair/Removal and Replacement/Piston and Connecting Rod - Removal 2. Remove No. 1 and No.2 piston rings from piston using a ring expander tool. 3. Remove upper oil ring side rail. 4. Remove lower oil ring side rail. 5. Remove oil ring expander Piston Ring(s) - Installation INSTALLATION 1. Measure clearance of piston rings to the cylinder bore and piston. See: Procedures The No. 1 and No. 2 piston rings have a different cross section. Ensure that which ever design No. 2 ring is installed, it is installed with manufacturers I.D. mark (dot) facing up, towards top of the piston See: Description and Operation. CAUTION: Install piston rings in the following order: Do not use a piston ring expander during this step. - Oil ring expander. - Lower oil ring side rail. - Upper oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures > Page 2030 2. Install the side rail (1) by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. The No. 1 and No. 2 piston rings have a different cross section. Ensure that when the No. 2 ring is installed, it is installed with manufacturers I.D. mark facing up, towards top of the piston See: Description and Operation. 3. Install upper side rail first and then the lower side rail. 4. Install the No. 2 piston ring and then No. 1 piston ring. 5. Position piston ring end gaps. 6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm - Description Rocker Arm Assembly: Description and Operation Rocker Arm - Description ROCKER ARM Rocker arms are made of light weight permanent mold aluminum alloy with a roller type follower operating against the camshaft. The valve actuating end of the rocker arms are machined to retain hydraulic lash adjusters, eliminating the need for manual valve lash adjustment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm - Description > Page 2039 Rocker Arm Assembly: Description and Operation Rocker Arm - Operation OPERATION The rocker arm is the pivot point between the camshaft lobe and the valve. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm - Description > Page 2040 Rocker Arm Assembly: Description and Operation Rocker Arm Shaft - Description ROCKER ARM SHAFTS The rocker arm shafts are tubular steel and supported by several forged aluminum alloy pedestals, which are fastened to the cylinder head. Four shafts are used, one for each intake and exhaust rocker arm bank on each cylinder head. The shafts are hollow to provide a duct for lubricating oil flow from the cylinder head to the valve mechanisms. One hollow dowel per pedestal is used to locate the pedestal to the cylinder head, orient the exhaust rocker shaft, and serve as a cam bearing oil feed passage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures INSPECTION The rocker arm shafts are hollow and are used as lubrication oil ducts. The rocker arm and shaft assembly on the right side of the engine has an oil passage hole from the cylinder head located at the third rocker shaft support pedestal. The rocker arm and shaft assembly on the left side of the engine has an oil passage hole from the cylinder head located at the second rocker shaft support pedestal. NOTE: To prevent air ingestion into lash adjusters, avoid turning rocker arm assembly upside down. CAUTION: Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjuster and plastic retainer. The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly. Check rocker arms for wear or damage: - Roller scuffing or wear - Shaft bore scuffing or wear - Swivel pad on lash adjuster missing or broken - Rocker arm showing signs of fatigue or cracking - Roller axle protruding from arm Replace assembly as necessary if any rocker arms shows signs of wear. CAUTION: Do not remove lash adjuster from rocker arm assembly. Damage to the adjuster and rocker arm will result. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2043 Rocker Arm Assembly: Removal and Replacement Valve Rocker Arm - Removal REMOVAL 1. Remove the cylinder head covers See: Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. CAUTION: DO NOT use a number stamp or a punch to mark the rocker arms. Damage to the rocker arms could occur. 2. Using a permanent ink or paint marker, identify the location and position on each rocker arm. 3. Remove the rocker arm assembly bolts in the sequence shown. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2044 4. Remove the rocker arm assembly (2). NOTE: To prevent air ingestion into the lash adjusters, avoid turning the rocker arm assembly upside down. CAUTION: Do not allow rocker arm assembly to rest on lash adjusters, as damage may occur to lash adjusters and/or plastic retainers. Valve Rocker Arm - Disassembly DISASSEMBLY CAUTION: DO NOT use a number stamp or a punch to mark the rocker arms. Damage to the rocker arms could occur. 1. Using a permanent ink or paint marker, identify the location and position on each rocker arm and remove the rocker arm and shaft assembly See: Valve Rocker Arm - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2045 2. Remove the dowel pins using a 4 mm screw, nut, spacer, and washer installed into the pin. Thread the screw into the pin, then loosen the nut on the screw. This will pull the dowel out of the shaft support. Do not reuse the dowel pins. NOTE: The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head. 3. Remove the rocker arms and pedestals in order. 4. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or heavily worn. 5. Check the shaft oil holes for clogging with a small wire, clean as required. Valve Rocker Arm - Assembly ASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2046 CAUTION: The rocker arm shafts are hollow and are used as lubrication oil passages. The rocker arm and shaft assembly on the RIGHT side of the engine has an oil passage hole from the cylinder head to the third rocker shaft support. The rocker arm shaft assembly on the LEFT side of the engine has an oil passage hole from the cylinder head to the second rocker shaft support. NOTE: A new fully assembled rocker arm and shaft assembly can be installed on either the right or left side of the engine. The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head. 1. Position the shafts with the notches (1) facing up. Install the rocker arms and pedestals onto the shafts. CAUTION: New dowel pins must be installed when reassembling. 2. Install the dowel pins (2). The dowel pins (2) pass through the pedestal (3) into the exhaust rocker shafts. Dowel pins (2) should be pressed in until they bottom-out against the rocker shaft in the pedestal (3). 3. Install the rocker arm and shafts assembly See: Valve Rocker Arm - Installation Valve Rocker Arm - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2047 NOTE: The rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation. 1. Rotate camshaft gears clockwise to where the number one cylinder intake valves would just start to open. The camshaft lobes are now in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it. NOTE: A new fully assembled rocker arm and shaft assembly can be installed on either the right or left side of the engine. The identification marks (notches) (1) face toward the front of the engine for the left head and toward the rear of the engine for the right head. 2. Install the rocker arm and shaft assembly making sure that the identification marks (1) face toward the front of engine for left head and toward the rear of the engine for right head. 3. Tighten the rocker arm/shaft assembly bolts in the sequence shown to 31 Nm (275 in. lbs.). 4. Install the cylinder head covers See: Valve Cover/Service and Repair/Cylinder Head Cover(s) Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal Valve Cover: Service and Repair Cylinder Head Cover(s) - Removal Left REMOVAL WARNING: Do not start or run the engine with the cylinder head cover removed. Damage or personal injury may occur. 1. Disconnect and isolate the negative battery cable. 2. Disconnect and remove the three ignition coils See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil Removal. 3. Disconnect engine harness retaining clips (2) from cylinder head cover studs. Position the engine harness aside. 4. Disconnect the PCV hose (3) from the valve cover assembly (if required). 5. Completely loosen the eight cylinder head cover retaining bolts (4) and remove the cylinder head cover. Right REMOVAL WARNING: Do not start or run the engine with the cylinder head cover removed. Damage or personal injury may occur. 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold from the engine See: Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Cover lower intake manifold intake ports with a clean cover to prevent dirt or debris from entering the ports during service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2052 4. Disconnect the ignition coil harness connectors (2). 5. Remove ignition coils See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal. 6. Disconnect the engine wiring harness retainers (1) from the valve cover. 7. Disconnect the makeup air hose (3). 8. Completely loosen the cylinder head cover retaining bolts (4) and remove the cylinder head cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2053 Valve Cover: Service and Repair Cylinder Head Cover(s) - Installation Left INSTALLATION 1. Clean cylinder head and all gasket sealing surfaces. Inspect and replace gasket and seals as necessary. 2. Using a suitable pry tool, carefully remove spark plug tube seals (2). 3. Position new seal with the part number on seal facing cylinder head cover. 4. Install seals using Camshaft Installer MD-998306 (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2054 5. Install cylinder head cover and bolts (4). Tighten to 10 Nm (90 in. lbs.). 6. Install the PCV hose (3) (if required). 7. Position the wiring harness on the cylinder head cover. 8. Reinstall the wire harness retainers (2) around the perimeter of the valve cover. 9. Install the ignition coils See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Installation. 10. Connect the ignition coil electrical connectors (1). 11. Connect negative battery cable. Right INSTALLATION 1. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary. 2. Using a suitable pry tool, carefully remove tube seals (2). 3. Position new seal with the part number on seal facing cylinder head cover. 4. Install seals using Camshaft Installer MD-998306 (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2055 5. Install cylinder head cover bolts (4) and tighten to 10 Nm (90 in. lbs.). 6. Reconnect the wire harness retainers (1) to the valve cover. 7. Install the ignition coils See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Installation. 8. Connect the ignition coil electrical connectors (2). 9. Reconnect the makeup air hose (3). 10. Install upper intake manifold See: Intake Manifold/Service and Repair/Intake Manifold Installation. 11. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Description and Operation > Valve Springs - Description Valve Spring: Description and Operation Valve Springs - Description DESCRIPTION The valve springs are made from chrome silicon alloy wire and incorporate a "bee-hive" design. Valve spring retainers and locks are common from valve-to-valve. The valve spring seat is integral with the valve stem oil seal, which incorporates a garter spring to maintain consistent lubrication control to the valve stem. The valve springs are unique for intake compared to exhaust. Both have different lengths and are wound in opposite directions. The valve springs are color coded, intake spring is right hand coil direction with grey dye on the top coils, and the exhaust spring is left hand coil direction with a blue dye on the top coils. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Description and Operation > Valve Springs - Description > Page 2060 Valve Spring: Description and Operation Valve Springs - Operation OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures INSPECTION When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example; the compression length of the spring to be tested is 38.00 mm (1.496 in.). Turn table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inches.) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Engine Specifications to obtain specified height and allowable tensions See: Specifications/Engine Specifications. Replace springs that do not meet specifications. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2063 Valve Spring: Removal and Replacement Cylinder Head Off CYLINDER HEAD OFF 1. Compress valve spring with valve spring compressor C-3422-D and adapter 6526A See: Tools and Equipment. 2. Remove valve retaining locks. Release valve spring compressor. Remove valve spring retainer and valve spring. 3. Remove valve stem seal assembly. See: Seals and Gaskets/Valve Guide Seal/Service and Repair/Valve Guide Seals - Removal Cylinder Head On CYLINDER HEAD ON 1. Disconnect negative battery cable. 2. Remove upper intake manifold See: Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Remove cylinder head cover(s) See: Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 4. Remove rocker arm and shaft assembly See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Removal. 5. Remove spark plugs. 6. Rotate the crankshaft clockwise, until the number 1 piston is at TDC (Top Dead Center) on the compression stroke. 7. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 620.5 to 689 kPa (90 to 100 psi) air pressure. This is to hold valves into place while servicing components. NOTE: It may be necessary to use accessory studs 6886, adapter arm 6887 and 6885 valve adaptor along with MD 998772A, to compress the valve spring on the right cylinder head exhaust valves. 8. Using Tool MD 998772A (1), with adapter 6527 (4) or equivalent, compress valve spring and remove valve locks (5). Release tension on valve spring, remove retainer (5) and valve spring See: Tools and Equipment. 9. Remove valve stem seal, if required. See: Seals and Gaskets/Valve Guide Seal/Service and Repair/Valve Guide Seals - Removal 10. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston is at TDC in each cylinder of the valve spring that is being removed. 11. Remove spark plug adapter tool. Cylinder Head Off Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2064 CYLINDER HEAD OFF 1. Install valves if removed. 2. Install valve stem seal/spring seat assembly (5) over valve guides on all valve stems. Ensure that the garter spring is intact around the top of the rubber seal. 3. Place valve spring (color-coded end facing up) (4) and valve retainer into position. 4. Compress valve spring with valve spring compressor. Install locks and release tool. If valve and/or seat are reground, measure the installed height of springs (B), make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.5256 in.), install a 0.762 mm (0.030 in.) spacer in head counterbore under the valve spring seat to bring spring height back within specification. Cylinder Head On CYLINDER HEAD ON Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 2065 1. Install new valve seal(s) if required See: Seals and Gaskets/Valve Guide Seal/Service and Repair/Valve Guide Seals - Installation. 2. Place valve spring (color-coded end facing up) and valve retainer into position. NOTE: It may be necessary to use accessory studs 6886, adaptor arm 6887 and 6885 valve adaptor along with MD 998772A, to compress the valve spring on the right cylinder head exhaust valves. 3. Compress valve spring using Special Tool MD 998772A (1) with Adaptor 6527 (4), only enough to install locks (5). 4. After installing locks, release tension on valve spring and verify proper installation. 5. Remove Special Tool MD 998772A (1) and spark plug adapter tool. 6. Install rocker arm and shaft assembly. See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Installation 7. Install cylinder head cover(s) See: Valve Cover/Service and Repair/Cylinder Head Cover(s) Installation. 8. Install spark plugs. 9. Install upper intake manifold See: Intake Manifold/Service and Repair/Intake Manifold - Installation. 10. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Intake and Exhaust Valves - Description Valve: Description and Operation Intake and Exhaust Valves - Description DESCRIPTION Valves are made of highly heat-resistant steel and are chrome plated to prevent stem scuffing. The intake valve is a one-piece forging, while the exhaust valve has a forged head with a welded stem for lock groove durability. The four valves (two intake and two exhaust) employ a three-groove lock design to help facilitate valve rotation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Intake and Exhaust Valves - Description > Page 2070 Valve: Description and Operation Intake and Exhaust Valves - Operation OPERATION The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Intake and Exhaust Valves - Inspection Valve: Testing and Inspection Intake and Exhaust Valves - Inspection VALVES 1. Measure valve stems for wear approximately 60 mm (2.36 in.) below the valve lock grooves. 2. Compare measurement to specifications, See: Specifications/Engine - Specifications. NOTE: Valve stems are chrome plated and should not be polished. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Intake and Exhaust Valves - Inspection > Page 2073 Valve: Testing and Inspection Intake and Exhaust Valve Guides - Inspection VALVE GUIDES 1. Measure valve stem-to-guide clearance as follows: 2. Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat. A small piece of hose may be used to hold valve in place. 3. Attach dial indicator Tool C-3339A to cylinder head and set it at right angle of valve stem being measured. 4. Move valve to and from the indicator. 5. Note dial indicator reading and compare to engine specifications. See: Specifications/Engine - Specifications NOTE: Replace cylinder head if stem-to-guide clearance exceeds specifications, or if guide is loose in cylinder head. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures Valve: Procedures Intake and Exhaust Valves - Cleaning CLEANING 1. Clean all valves thoroughly and discard burned, warped and cracked valves. Valve and Valve Seat Refacing VALVE AND VALVE SEAT REFACING Refer to Engine Specifications for the valve face and valve seat angles See: Specifications/Engine - Specifications. VALVES 1. Inspect the remaining margin after the valves are refaced See: Specifications/Engine Specifications. VALVE SEATS 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for re-seating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed 0.051 mm (0.002 inch.) total indicator reading. 3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLYwith Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, then lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face, then raise valve seat with a 65 degree stone. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 2076 NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise, the cylinder head must be replaced. 4. When seat is properly positioned, the width of the intake seats should be 0.75 to 1.25 mm (0.0296 to 0.0493 in.) and exhaust seats should be 1.25 to 1.75 mm (0.049 to 0.069 in.). VALVE AND SPRING INSTALLED HEIGHT 1. Coat valve stems with clean engine oil and insert the valves into the cylinder head. 2. If valves or seats have been refaced, check valve tip height (A). If valve tip height is greater than 43.65 mm (1.7185 in.) intake or 45.98 mm (1.8102 in.) exhaust, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem. 3. Install valve seal/spring seat assembly over valve guides on all valve stems. Ensure that the garter spring is intact around the top of the valve seal. 4. Place valve spring (color-coded end facing up) and valve retainer into position on spring seat. 5. Compress valve springs with valve spring compressor C-3422-D and adapter 6526A See: Tools and Equipment, install locks and release tool. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 2077 6. If valves and/or seats are refaced, measure the installed height of springs. Measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.5256 in.), install a 0.762 mm (0.030 in.) spacer in head counterbore under the valve spring seat to bring spring height back within specification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 2078 Valve: Removal and Replacement Intake and Exhaust Valves - Removal REMOVAL 1. Remove cylinder head(s) See: Service and Repair/Removal and Replacement/Cylinder Head Removal. 2. Remove rocker arm assembly See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Removal. 3. Remove valve spring(s) See: Valve Spring/Service and Repair/Removal and Replacement/Valve Springs - Removal. 4. Before removing valve, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. 5. Remove valve(s) from cylinder head. Intake and Exhaust Valves - Installation INSTALLATION 1. Coat valve stems with clean engine oil and insert the valves into the cylinder head. 2. If valves or seats have been reground, check valve tip height (A). If valve tip height is greater than 43.65 mm (1.7185 in.) intake or 45.98 mm (1.8102 in.) exhaust, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem. 3. Install new valve stem seals. 4. Install valve springs See: Valve Spring/Service and Repair/Removal and Replacement/Valve Springs - Installation. 5. Install cylinder head(s) See: Service and Repair/Removal and Replacement/Cylinder Head - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION ACCESSORY DRIVE BELT - WORLD ENGINE The accessory drive belt is a Poly-V type belt. On the 2.4L engine, the accessory drive belt drives the generator, P/S pump and air conditioning compressor. ACCESSORY DRIVE BELT -3.5L Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 2083 On the 3.5L, the accessory drive belt drives the generator, P/S pump, and A/C compressor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 2084 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELTS Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. ACCESSORY DRIVE BELT DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures Serpentine Accessory Drive Belt - Cleaning CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Serpentine Accessory Drive Belt - Inspection INSPECTION Belt replacement under any or all of the following conditions is required: - Excessive wear - Frayed cords - Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not. NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2087 Drive Belt: Removal and Replacement Serpentine Accessory Drive Belt - Removal 3.5L ENGINE ACCESSORY DRIVE BELT -3.5L 1. Raise vehicle on hoist. 2. Remove RH wheelhouse splash shield.See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 3. Rotate accessory drive belt tensioner (3) clockwise to allow enough slack to remove accessory drive belt (5). Serpentine Accessory Drive Belt - Installation 3.5L ENGINE ACCESSORY DRIVE BELT -3.5L Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2088 1. Position accessory drive belt (5) on all pulleys except generator (6). 2. Rotate accessory drive belt tensioner (3) clockwise. 3. Position accessory drive belt (5) on generator pulley (6). 4. Slowly release accessory drive belt tensioner (3). 5. Install RH wheelhouse splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield Installation 6. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Removal 3.5L ENGINE WARNING: Because of high spring pressure, do not attempt to disassemble automatic tensioner. Unit is serviced as an assembly. 1. Remove the passenger side engine support bracket bolts (1). 2. Raise and support the vehicle. 3. Remove the accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 4. Remove the belly pan retainers (1). 5. Remove the belly pan (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 2093 6. Support the engine fore/aft crossmember (2) with an appropriate stand (1). 7. Loosen the rear bolts (2) from the fore/aft crossmember (1). 8. Remove the front bolts from the fore/aft crossmember. 9. Lower the stand supporting the fore/aft crossmember approximately 3/4" to 1". 10. Remove the tensioner assembly bolt (2). 11. Remove the accessory drive belt tensioner (1) from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 2094 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Installation 3.5L ENGINE 1. Position the accessory drive belt tensioner (1) on the front engine cover (3). 2. Install the mounting bolt (2). Tighten the bolt to 41 Nm (30 ft. lbs.). 3. Raise the fore/aft crossmember (1) approximately 3/4" to 1". 4. Install the front fore/aft crossmember bolts. Tighten the bolts to 55 Nm (41 ft. lbs.). 5. Tighten the rear fore/aft crossmember bolts (2) to 55 Nm (41 ft. lbs.). 6. Remove the stand (1) from the fore/aft crossmember (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 2095 7. Install the belly pan (2). 8. Install accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 9. Lower the vehicle. 10. Install the three bolts (1) at the passenger side engine support bracket. Tighten the bolts to 45 Nm (33 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal Engine Mount: Service and Repair Engine Mount Insulator - Removal Left REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove air cleaner housing assembly (4) See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 3. Remove the belly pan (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2100 4. Support transmission with floor jack and wooden block. 5. Remove the vertical bolts (1) from the left engine mount (2) to transmission bracket. 6. Slightly lower transmission with floor jack to gain access to mount to frame rail fastener (2). 7. Remove mount isolator (3). Rear REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2101 1. Remove the belly pan (2). 2. Remove the Power Transfer Unit (PTU). See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/Power Transfer Unit - Removal 3. Remove the 3 top mount bracket bolts (1). 4. Remove the 4 lower mount to cradle bolts (2). 5. Remove rear mount (3). Front REMOVAL 1. Raise vehicle. 2. Remove the belly pan (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2102 3. Remove fore aft member (3) to mount (4) bolts. 4. Remove mount through bolt (1). 5. Remove fore aft member (3) mounting bolts and remove. 6. Remove front mount (4). Right REMOVAL 1. Remove the belly pan (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2103 2. Lower vehicle. Remove the load on the engine motor mounts by carefully supporting the engine assembly from below. 3. Remove Power Steering Fluid Reservoir and set aside See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 4. Disconnect the ground strap. 5. Remove the right engine support bracket vertical fasteners (1) and (2) and remove support bracket (3). 6. Remove the bolts (5) attaching the right isolator (4) to the frame rail. 7. Remove right isolator (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2104 Engine Mount: Service and Repair Engine Mount Insulator - Installation Left INSTALLATION 1. Position mount isolator (3) in place, install bolts (1, 2) and tighten to 50 Nm (37 ft. lbs.). 2. Raise transaxle into position, install bolts (2) and tighten to 98 Nm (72 ft. lbs.). 3. Remove floor jack and wooden block. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2105 4. Install belly pan (2). 5. Install the air cleaner housing assembly (4) See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 6. Connect negative battery cable. Rear INSTALLATION 1. Position rear mount (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2106 2. Install the 4 lower mount to cradle bolts (2) and torque to 50 Nm (37 ft. lbs.). 3. Install 3 top mount bracket bolts and torque 50 Nm (37 ft. lbs.). 4. Install the Power Transfer Unit (PTU). See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/Power Transfer Unit - Installation. 5. Install the belly pan (2). Front INSTALLATION 1. Position mount (4) and torque bolts to 47 Nm (35 ft. lbs.). 2. Install fore aft member (3) and torque bolts to 100 Nm (74 ft. lbs.). 3. Install mount through bolt (1) and torque to 47 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2107 4. Install the belly pan (2). 5. Lower vehicle. Right INSTALLATION 1. Position right isolator (4) and install the isolator to frame rail bolts (5). Tighten bolts to 55 Nm (40 ft. lbs.). 2. Install the engine support bracket (3) and bolts (1). Tighten bolts to 50 Nm (37 ft. lbs). 3. Install the support bracket to isolator nuts (2) and tighten to 30 Nm (22 ft. lbs). 4. Reconnect the ground strap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2108 5. Raise vehicle on a hoist. 6. Install the belly pan (2). 7. Install power steering reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Accessory Drive Idler Pulley - Installation Idler Pulley: Service and Repair Accessory Drive Idler Pulley - Installation 3.5L ENGINE 1. Position idler pulley and bolt. 2. Tighten bolt to 35 Nm (25 ft. lbs.). 3. Install accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE NOTE: At Normal Operating Temperatures Pressure @ Curb Idle Speed *............................................................................................................. .......................................34.47 kPa Min. (5 PSI MIN.) Pressure @ 3000 RPM.................................... ...............................................................................................................................300-724 kPa (45-105 PSI.) *CAUTION: If pressure is zero at curb idle, DO NOT run engine at 3000 RPM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2117 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE Check oil pressure using a gauge at oil pressure switch location (7). 1. Remove the oil pressure switch (7) See: Oil Pressure Switch (For Fuel Pump)/Service and Repair/Oil Pressure Switch - Removal. 2. Install oil pressure test gauge, Special Tool C-3292A with Adapter 8406. For Special Tool identification, See: Tools and Equipment. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM. 3. Warm engine to normal operating temperature. 4. Monitor gauge readings at idle and 3000 rpm. For specifications See: Specifications/Engine - Specifications. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2122 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ............................................................. 5.2L (5.5 qts) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2125 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ...................................... API SAE Certified 10W-30 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2126 Engine Oil: Description and Operation ENGINE OIL WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. When service is required, Chrysler recommends that only Mopar(R) brand parts, lubricants and chemicals be used. Mopar(R) provides the best engineered products for servicing Chrysler vehicles. Only lubricants bearing designations defined by the following organization should be used. - Society of Automotive Engineers (SAE) - American Petroleum Institute (API) - National Lubricating Grease Institute (NLGI) - Association des Constructeurs Europeens d' Automobiles (European Automobile Manufacturers Association) (ACEA) API CERTIFICATION AND LICENSE SYMBOL Use an engine oil that is API Certified and Licensed to display the certification mark. MOPAR(R) provides engine oils that meet or exceed, Material Standard MS-6395 requirement. SAE VISCOSITY Engine oils are designed to improve low temperature starting and vehicle fuel economy. Refer to the engine oil filler cap for the preferred engine oil viscosity grade for each vehicle. SAE viscosity grades are used to specify the correct viscosity oil for an engine. Use only Multi-Viscosity oils. These are specified with a dual SAE viscosity grade which indicates the cold (5W) to hot (20, 30) temperature performance range of the oil. ACEA CATEGORIES For countries that use the ACEA European Oil Categories for service fill oils, use engine oils that meet the requirements of ACEA A1/B1, A2/B2, or A3/B3. CONTAINER IDENTIFICATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2127 The Engine Oil Certification Mark was developed and trademarked by the API to refer customers to those engine oils preferred by the automobile manufacturers. This symbol means that the oil has been certified and licensed by the American Petroleum Institute (API). This certification mark will only be found on the front of the oil containers. Those oils that do not display the "Mark" on the front of the container should not be used. Chrysler only recommends API Certified engine oils that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395. SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that are certified by the American Petroleum Institute (API) to display the "Certification Mark" and show SAE viscosity grade recommended for each vehicle. Follow the service schedule that describes your driving type. ENGINE OIL ADDITIVES/SUPPLEMENTS The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines and emission systems by: - Increasing the level of Phosphorus and Sulfur in the engine oil. The API Certified Engine Oils control the Phosphorus and Sulfur contents of the oil to levels that reduce the contamination effect on the vehicles emission control system. - Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. - Creating potential for an undesirable additive compatibility interaction in the engine crankcase. The engine oils contain a performance additive system carefully developed to optimize the oils performance in the engine. The addition of supplements may cause the oil to thicken prematurely, cause excessive deposit build-up and potentially shorten engine life. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil. CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 2130 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. See: Maintenance WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. TO CHANGE ENGINE OIL 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Open hood, remove engine oil fill cap (1). 4. Raise vehicle on hoist. 5. Place a suitable drain pan under crankcase drain. 6. Remove oil pan drain plug (1) from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (2). 8. Install drain plug (1) in crankcase. Tighten oil pan drain plug to 27 Nm (20 ft. lbs.). 9. Install new oil filter (2). 10. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 2131 11. Fill crankcase with specified type and amount of engine oil. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Description and Operation 12. Install oil fill cap (1). 13. Start engine and inspect for leaks. 14. Turn engine off and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. When replacing oil filter, use a Mopar(R) filter or equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING above. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures Oil Filter: Procedures ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. See: Maintenance WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. TO CHANGE ENGINE OIL 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Open hood, remove engine oil fill cap (1). 4. Raise vehicle on hoist. 5. Place a suitable drain pan under crankcase drain. 6. Remove oil pan drain plug (1) from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (2). 8. Install drain plug (1) in crankcase. Tighten oil pan drain plug to 27 Nm (20 ft. lbs.). 9. Install new oil filter (2). 10. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 2136 11. Fill crankcase with specified type and amount of engine oil. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Description and Operation 12. Install oil fill cap (1). 13. Start engine and inspect for leaks. 14. Turn engine off and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. When replacing oil filter, use a Mopar(R) filter or equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING above. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 2137 Oil Filter: Removal and Replacement Engine Oil Filter - Removal REMOVAL NOTE: When servicing the oil filter, avoid deforming the filter can. Install the remove/install tool band strap against the base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using a suitable oil filter wrench, unscrew filter (2) from base and discard. Engine Oil Filter - Installation INSTALLATION All engines are equipped with a high quality full-flow, disposable type oil filter (2). When replacing oil filter, use a Mopar(R) filter or equivalent. 1. Wipe base clean, then inspect gasket contact surface. 2. Lubricate gasket of new filter with clean engine oil. 3. Install and tighten oil filter (2) to 16 Nm (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary. 4. Start engine and check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications OIL PAN Tighten the oil pan bolts to 28 Nm (21 ft. lbs.). Tighten the oil pan bell housing bolts to 55 Nm (40 ft. lbs.). Tighten the oil pan drain bolt (1) to 27 Nm (20 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal Oil Pan: Service and Repair Engine Oil Pan - Removal REMOVAL 1. Disconnect negative battery cable (1). 2. Remove the engine oil indicator (1). 3. Remove the engine oil indicator tube bolt (3). 4. Remove the engine oil indicator tube (2). 5. Raise and support the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2143 6. Remove the front crossmemberSee: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal. 7. Remove the crossover pipeSee: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold - Removal. 8. Loosen the front exhaust manifoldSee: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold Removal. 9. Remove the oil pan bell housing bolts (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2144 10. Drain the engine oil (1). 11. Remove the engine oil filter (2). 12. Remove the oil pan fasteners. Remove the oil pan. NOTE: A small amount of oil will remain in the oil pan. Use care when removing the oil pan from the engine. 13. Remove oil pan gasket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2145 Oil Pan: Service and Repair Engine Oil Pan - Installation INSTALLATION 1. Clean oil pan and all gasket surfaces. 2. Apply a 1/8 inch bead of Mopar(R) Engine RTV GEN II at the parting line of the oil pump housing and the rear seal retainer. 3. Install oil pan gasket to the engine block. 4. Install the oil pan and tighten the oil pan bolts to 28 Nm (21 ft. lbs.). 5. Tighten the oil pan bell housing bolts to 55 Nm (40 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2146 6. All engines are equipped with a high quality full-flow, disposable type oil filter (2). When replacing oil filter, use a Mopar(R) filter or equivalent. 7. Wipe base clean, then inspect gasket contact surface. 8. Lubricate gasket of new filter with clean engine oil. 9. Install and tighten oil filter (2) to 16 Nm (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary.Lower vehicle. 10. Install and tighten the oil pan drain bolt (1) to 27 Nm (20 ft. lbs.). 11. Tighten the front maniverter boltsSee: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold Removal. 12. Install the crossover pipeSee: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2147 13. Install the front crossmemberSee: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal. 14. Lower vehicle. 15. Install the oil level indicator tube (2). 16. Tighten the oil level indicator tube bolt (3). 17. Install the oil indicator (1). 18. Fill engine crankcase with proper oil to correct level. 19. Connect negative battery cable (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2151 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2152 Oil Pressure Sender: Diagrams Connector (GAS) - (ENGINE) 2 WAY SWITCH-OIL PRESSURE (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 2157 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE NOTE: At Normal Operating Temperatures Pressure @ Curb Idle Speed *............................................................................................................. .......................................34.47 kPa Min. (5 PSI MIN.) Pressure @ 3000 RPM.................................... ...............................................................................................................................300-724 kPa (45-105 PSI.) *CAUTION: If pressure is zero at curb idle, DO NOT run engine at 3000 RPM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2162 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE Check oil pressure using a gauge at oil pressure switch location (7). 1. Remove the oil pressure switch (7) See: Oil Pressure Switch (For Fuel Pump)/Service and Repair/Oil Pressure Switch - Removal. 2. Install oil pressure test gauge, Special Tool C-3292A with Adapter 8406. For Special Tool identification, See: Tools and Equipment. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM. 3. Warm engine to normal operating temperature. 4. Monitor gauge readings at idle and 3000 rpm. For specifications See: Specifications/Engine - Specifications. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures Oil Pressure Regulator Valve: Procedures INSPECTION 1. Inspect oil pressure relief valve (1) plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper. 2. The relief valve spring (2) has a free length of approximately 49.5 mm (1.95 in.) it should test between 101-110 N (23-25 lbs.) when compressed to 34 mm (1.34 in.). Replace spring that fails to meet specifications. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures > Page 2167 Oil Pressure Regulator Valve: Removal and Replacement Oil Pressure Relief Valve - Removal REMOVAL 1. Remove the oil pan. See: Oil Pan/Service and Repair/Engine Oil Pan - Removal 2. To remove the relief valve, proceed as follows: a. Remove the cotter pin that retains the retainer cap. b. Drill a 3.175 mm (1/8 inch.) hole into the relief valve retainer cap c. Insert a self-threading sheet metal screw into cap. d. Using a suitable slide hammer tool, remove retainer cap. Discard retainer cap e. Remove spring (2) and relief valve (1). Oil Pressure Relief Valve - Installation INSTALLATION 1. Lubricate relief valve (1) with oil. CAUTION: The pressure relief valve must be installed as shown in , or engine damage may occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures > Page 2168 2. Install valve (1), spring (2) and retainer cap. 3. Install new cotter pin (4). 4. Install the oil pan. See: Oil Pan/Service and Repair/Engine Oil Pan - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications INTAKE MANIFOLD Intake Manifold - Lower........................................................................................................................ ....................................................28 Nm (250 in.lbs.) Intake Manifold - Upper........................................................................................................................ ....................................................12 Nm (105 in.lbs.) (Tighten bolts gradually starting in the center working outward) THROTTLE BODY CAUTION:The throttle body must be torqued in a mandatory torque sequence. Tighten in a criss cross pattern to specification. Tighten the three bolts and one stud in a mandatory torque criss - cross pattern sequence to 5.5 Nm (50 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal Intake Manifold: Service and Repair Intake Manifold - Removal Lower LOWER INTAKE MANIFOLD 1. Disconnect the negative battery cable (1). 2. Perform fuel pressure release procedure. See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 3. Drain the cooling system See: Cooling System/Service and Repair. 4. Disconnect the upper radiator hose (1) from the thermostat housing (2). 5. Remove the upper intake manifold See: . 6. Disconnect the electrical connectors to fuel injectors and coolant temperature sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2174 7. Disconnect heater supply and return hoses from the thermostat housing. 8. Disconnect the fuel line from the fuel rail. 9. Remove the 4 bolts attaching fuel rail. 10. Remove fuel rail and injectors as an assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2175 11. Remove lower intake 4 bolts and position the ignition coil capacitor aside. 12. Remove the lower intake manifold (1). Upper REMOVAL - UPPER INTAKE MANIFOLD 1. Remove engine cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2176 2. Disconnect negative battery cable. 3. Remove air cleaner housing (4) and inlet hose (1) See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 4. Disconnect the EGR tube See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Valve/Service and Repair/Exhaust Gas Recirculation (EGR) Valve - Removal. 5. Disconnect the following vacuum hoses from the upper intake manifold: - Positive Crankcase Ventilation (PCV) Valve (1) - EVAP Purge Solenoid (2) - EGR Tube (3) - Power Brake Booster (4) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2177 6. Disconnect electrical connectors from the following sensors and actuators: - Manifold Tuning Valve (MTV) (1) - Short Runner Valve (2) - Throttle Position Sensor (TPS) (3) - Manifold Absolute Pressure (MAP) (4) 7. Remove the Manifold Tuning Valve (5), then Remove the 2 nuts (1) and (2) from the rear intake manifold brackets. 8. Loosen the 2 bolts (3) and (4) from rear intake manifold brackets and position brackets aside. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2178 9. Remove the 7 upper intake manifold retaining bolts (1) and the upper intake manifold (2). Clean all gasket sealing surfaces. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2179 Intake Manifold: Service and Repair Intake Manifold - Installation Lower LOWER INTAKE MANIFOLD 1. Clean all sealing surfaces. 2. Position new gaskets and intake manifold on cylinder head surfaces. 3. Position the ignition coil capacitor and install the intake manifold bolts. Gradually tighten in sequence shown until a torque of 28 Nm (250 in. lbs.) is obtained. 4. Install fuel rail and injectors as an assembly. 5. Connect fuel supply hose to fuel rail. 6. Connect heater supply and return hoses to the intake manifold. 7. Connect electrical connectors to fuel injectors and coolant temperature sensor. 8. Install upper intake manifold See: . 9. Connect upper radiator hose to thermostat housing. 10. Fill cooling system See: Cooling System/Service and Repair. 11. Connect negative battery cable See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection. Upper INSTALLATION - UPPER INTAKE MANIFOLD 1. Clean and inspect gasket sealing surfaces. 2. Position new gasket. 3. Install the throttle body on the upper intake (if required)See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Throttle Body - Installation. 4. Install upper intake manifold (2) and hand start all attaching bolts (1). 5. Tighten bolts gradually starting in the center working outward until a torque of 12 Nm (105 in. lbs.) is obtained. 6. Install the rear intake manifold brackets to the head. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2180 7. Install the 2 intake manifold to bracket nut retainers. 8. Install the EGR tube See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Valve/Service and Repair/Exhaust Gas Recirculation (EGR) Valve - Installation. 9. Connect electrical connectors to the following sensors and actuators: - Manifold Tuning Valve (MTV) (1) - Short Runner Valve (2) - Throttle Position Sensor (TPS) (3) - Manifold Absolute Pressure (MAP) (4) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold - Removal > Page 2181 10. Connect the following vacuum hoses to the upper intake manifold: - Positive Crankcase Ventilation (PCV) Valve (1) - EVAP Purge Solenoid (2) - EGR Tube (3) - Power Brake Booster (4) 11. Install air cleaner housing (4) and inlet hose (1) See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. 12. Connect negative battery cable See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection. 13. Install the engine cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal Camshaft Oil Seal: Service and Repair Camshaft Seal(s) - Removal REMOVAL 1. Perform the fuel pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 2. Disconnect the negative battery cable (1). 3. Drain cooling system See: Cooling System/Service and Repair. 4. Remove the engine cover. 5. Remove air cleaner element housing See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2187 6. Remove the coolant recovery container (1) See: Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal. 7. Remove the generator.See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator - Removal. 8. Disconnect the fuel line (1) at the fuel rail (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2188 9. Remove the upper intake manifold (2)See: Intake Manifold/Service and Repair/Intake Manifold Removal. 10. Remove the fuel rail See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Rail/Service and Repair/Fuel Rail - Removal. 11. Remove the lower intake manifold (1) See: Intake Manifold/Service and Repair/Intake Manifold - Removal. 12. Raise the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2189 13. Remove right exhaust manifold See: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold Removal. 14. Remove right front tire. 15. Remove right inner splash shield. 16. Remove accessory drive belt (7). 17. Remove vibration damper (5)See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Removal. 18. Remove lower accessory drive belt idler pulley (6). 19. Remove lower outer timing belt cover bolts. 20. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2190 21. Remove the upper accessory drive belt idler pulley (2). 22. Remove the belt tensioner. 23. Support the engine with a block of wood and a floor jack. 24. Remove the upper engine mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator Removal. 25. Remove the power steering reservoir bolts and set reservoir aside. 26. Remove the remaining outer timing belt cover bolts and cover. 27. Remove the timing belt See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Removal. 28. Remove the right valve cover to cylinder head ground strap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2191 29. Remove the EGR valve (1) and tube assembly (2). 30. Remove the right cylinder head cover. 31. Remove the right rocker arm and shaft assembly (2) See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Disassembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2192 32. Counterhold the cam gear and loosen the right cam gear retaining bolt. 33. Remove the inner timing cover to right cylinder head retaining bolts. 34. Remove the right rear camshaft thrust plate (1). 35. Carefully push the camshaft out of the back of the cylinder head approximately 3.5 inches. Remove the camshaft sprocket and bolt. 36. NOTE: It may be necessary to raise the engine slightly in order to remove the camshaft sprocket bolt. 37. Remove the cylinder head bolts in REVERSE of tightening sequence. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2193 NOTE: Because of clearance restrictions when removing the right cylinder head, the front four cylinder head bolts must be loosened, raised and supported with rubber bands before the cylinder head can be removed. 38. Remove the cylinder head. 39. Clean and inspect all mating surfaces. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2194 Camshaft Oil Seal: Service and Repair Camshaft Seal(s) - Installation INSTALLATION RIGHT CYLINDER HEAD 1. Position the camshaft seal into the cylinder head (3). 2. Using Camshaft installer MD-998306 (2) tap the seal into place using a mallet (1). 3. Apply light coat of clean engine oil to the camshaft oil seal lip (3) and Seal Protector Sleeve 6788 (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2195 NOTE: When installing the camshaft (1) into the cylinder head (4), you must first insert Seal Protector Sleeve 6788 (2) through the camshaft seal (3) until the camshaft seats, then remove Seal Protector Sleeve 6788 (2) from the camshaft. 4. Install the camshaft using Seal Protector Sleeve 6788. 5. Install the right cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head Installation. LEFT CYLINDER HEAD 1. Position the camshaft seal into the cylinder head (3). 2. Using Camshaft installer MD-998306 (2) tap the seal into place using a mallet (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair > Camshaft Seal(s) - Removal > Page 2196 3. Apply light coat of clean engine oil to the camshaft oil seal lip (3) and Seal Protector Sleeve 6788 (2). NOTE: When installing the camshaft (1) into the cylinder head (4), you must first insert Seal Protector Sleeve 6788 (2) through the camshaft seal (3) until the camshaft seats, then remove Seal Protector Sleeve 6788 (2) from the camshaft. 4. Install the camshaft using Seal Protector Sleeve 6788. 5. Install the left cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal Front Crankshaft Seal: Service and Repair Front Crankshaft Oil Seal - Removal REMOVAL 1. Remove the crankshaft sprocket. See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Removal. 2. Tap the dowel pin (2) out of the crankshaft. 3. Remove crankshaft seal using Special Tool 6341A (1). CAUTION: Do not nick shaft seal surface or seal bore. 4. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal > Page 2201 Front Crankshaft Seal: Service and Repair Front Crankshaft Oil Seal - Installation INSTALLATION 1. Install crankshaft seal using Special Tool 6342 (1). 2. Install the dowel pin into the crankshaft to 1.2 mm (0.047 in.) protrusion. 3. Install the crankshaft sprocket. See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Guide Seals - Installation Valve Guide Seal: Service and Repair Valve Guide Seals - Installation INSTALLATION 1. The valve stem seal/valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not remove garter spring (2) around the seal at the top of the valve stem seal. 2. Install valve spring. See: Cylinder Head Assembly/Valve Spring/Service and Repair/Removal and Replacement/Valve Springs - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2210 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2211 Oil Pressure Sender: Diagrams Connector (GAS) - (ENGINE) 2 WAY SWITCH-OIL PRESSURE (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 2216 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT SPROCKET Camshaft Sprocket Bolt-Right Side.........................................................................................................................102 + 1/4 Turn Nm (75 + 1/4 Turn ft.lbs) Camshaft Sprocket Bolt-Left Side...........................................................................................................................102 + 1/4 Turn Nm (75 + 1/4 Turn ft.lbs) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal CAMSHAFT SPROCKETS CAUTION: The 3.5L engine is NOT a free-wheeling design. Therefore, care should be taken not to rotate the camshafts or crankshaft with the timing belt removed. NOTE: The camshaft timing gears are keyed to the camshaft. 1. Perform fuel pressure release procedure. See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 2. Remove front timing belt cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 3. Position crankshaft sprocket to the TDC mark on the oil pump housing by turning crankshaft in the clockwise direction 4. Install a dial indicator in number 1 cylinder to check TDC of the piston. Rotate the crankshaft until the piston is at exactly TDC. 5. Remove camshaft retainer/thrust plate from rear of right cylinder head. 6. Remove the cylinder head covers. 7. Remove rocker arm assemblies. 8. Remove the timing belt tensioner and timing belt. 9. Loosen and remove the left camshaft gear retaining bolt and washer. The left bolt is 255 mm (10.0 in.) long. NOTE: The camshaft timing gears are keyed to the camshaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2223 10. Hold the left camshaft sprocket with 36 mm (1 7/16 in.) box end wrench. 11. Remove the left camshaft sprocket. CAUTION: The camshaft must be pushed rearward approximately 3 1/2 inches to remove the camshaft gear retaining bolt and gear. Care must be taken not to scratch or nick the camshaft or cylinder head journals when moving camshaft. 12. Loosen and remove the right camshaft gear retaining bolt and washer. The right bolt is 213 mm (8 3/8 in.) long. NOTE: The camshaft timing gears are keyed to the camshaft. 13. Hold the right camshaft sprocket with 36 mm (1 7/16 in.) box end wrench and loosen the camshaft bolt. 14. Using a floor jack, raise the right side of the engine enough to allow clearance to remove the right camshaft bolt and washer. 15. Remove the right camshaft sprocket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2224 Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation CAMSHAFT SPROCKETS CAUTION: The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up. CAUTION: The camshafts must be pushed back into the cylinder head after the camshaft sprockets and retaining bolts are positioned. Care must be taken not to scratch or nick the camshaft or cylinder head journals when moving the camshafts. 1. Install the camshaft sprockets onto the camshafts. Install NEW sprocket attaching bolts into place. The 255 mm (10 in.) bolt is installed in the left camshaft and the 213 mm (8 3/8 in.) bolt is installed into the right camshaft. Do not tighten the bolts at this time, they will be tightened at a later step. Camshaft sprocket timing marks should be aligned with inner cover timing marks at both sprockets. 2. Install the camshaft thrust plates (1) and seals. Tighten the bolts (2) to 28 Nm (250 in. lbs.). 3. Install the timing belt starting first at the crankshaft sprocket, then to remaining sprockets in a counterclockwise direction. 4. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley. Camshaft sprocket timing marks (1) and crankshaft sprocket timing mark (3) should still be aligned with the inner cover marks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2225 NOTE: It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner. See Timing Belt Removal for tensioner compression procedure See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal . 5. Hold the tensioner pulley against the belt and install the reset (pinned) timing belt tensioner (2) into the housing. Tighten attaching bolts to 28 Nm (250 in. lbs.). 6. Remove tensioner retaining pin to allow the tensioner to extend to the pulley bracket. 7. Hold the right camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the right camshaft bolt to 102 Nm (75 ft. lbs.) +90° turn. 8. Hold the left camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the left camshaft bolts to 102 Nm (75 ft. lbs.) +90° turn. 9. Install the rocker arm assemblies and cylinder head covers See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair/Removal and Replacement/Valve Rocker Arm - Installation 10. Install the front timing belt cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2226 Camshaft Gear/Sprocket: Service and Repair Crankshaft Sprockets - Installation CRANKSHAFT SPROCKET CAUTION: To ensure proper installation depth of crankshaft sprocket, Sprocket Installer 6641 must be used. 1. Install crankshaft sprocket using Special Tools 6641 and C-4685-C1. 2. Install timing belt, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Procedures Timing Belt: Procedures TIMING BELT 1. Remove front timing belt cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) Removal. 2. Inspect both sides of the timing belt. Replace belt if any of the following conditions exist: a. Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail. b. Cracks on rubber back. c. Cracks or peeling of canvas. d. Cracks on rib root. e. Cracks on belt sides. f. Missing teeth. g. Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. h. Vehicle mileage or time at component maintenance requirement. See: Maintenance 3. If none of the above conditions are seen on the belt, the front timing belt cover can be installed See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Procedures > Page 2231 Timing Belt: Removal and Replacement Timing Belt & Sprockets - Removal TIMING BELT 1. Perform fuel pressure release procedure. See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 2. Disconnect negative battery cable. 3. Remove both cylinder head covers. 4. Remove the front timing belt cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 5. Mark belt running direction, if timing belt is to be reused. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. 6. Rotate engine clockwise until crankshaft mark aligns with the TDC mark on oil pump housing and the camshaft sprocket timing marks are aligned with the marks on the rear cover. 7. Remove the timing belt tensioner and remove timing belt. 8. Inspect the tensioner for fluid leakage. 9. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If not rotating freely, replace the arm and pulley assembly. 10. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This ensures proper pin orientation when tensioner is installed on the engine. a. Place the tensioner into a vise and SLOWLY compress the plunger. Total bleed down of tensioner should take about 5 minutes. b. When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed. Timing Belt & Sprockets - Installation TIMING BELT CAUTION: The 3.5L is NOT a freewheeling engine. Therefore, the valve train rocker assemblies must be removed before attempting to rotate either crankshaft or camshafts independently of each other. CAUTION: If camshafts have moved from the timing marks, always rotate camshaft towards the direction nearest to the timing marks (DO NOT TURN CAMSHAFTS A FULL REVOLUTION OR DAMAGE to valves and/or pistons could result). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Procedures > Page 2232 TIMING GEAR ALIGNMENT 1. Align the crankshaft sprocket (10) with the TDC mark (9) on the oil pump cover. 2. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover. 3. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket and maintain tension on the belt as it is positioned around the tensioner pulley (11). NOTE: It is necessary to compress the plunger into the tensioner body and install a locking pin prior to reinstalling the tensioner. See Timing Belt Removal for tensioner compression procedure See: Timing Belt & Sprockets - Removal . 4. Hold the tensioner pulley (11) against the belt and install the reset (pinned) timing belt tensioner (2) into the housing. Tighten attaching bolts to 28 Nm (250 in. lbs.). 5. When tensioner (12) is in place, pull the retaining pin to allow the tensioner to extend to the pulley bracket. 6. Rotate the crankshaft sprocket (10) two revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure. 7. Install the front timing belt cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation. 8. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Timing Belt Tensioner-Bolts................................................................................................................. ....................................................28 Nm (250 in.lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal Timing Belt Tensioner: Service and Repair Engine Timing Tensioner - Removal Tensioner TENSIONER 1. For timing belt tensioner removal procedure, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal . Tensioner Pulley Assembly TENSIONER PULLEY ASSEMBLY 1. Remove the timing belt, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal. 2. Remove the timing belt tensioner pulley and bracket assembly by unscrewing the pivot bolt from the oil pump housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal > Page 2238 Timing Belt Tensioner: Service and Repair Engine Timing Tensioner - Inspection Tensioner TENSIONER 1. Inspect hydraulic tensioner for fluid loss around the plunger seal. Replace tensioner if leaking. Tensioner Pulley Assembly TENSIONER PULLEY ASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal > Page 2239 NOTE: The tensioner pulley, bracket, and pivot bolt is serviced as an assembly. 1. Inspect pulley for free movement. Replace if pulley is loose, seized, or rough turning. 2. Inspect pulley bearing and seal. Replace if damaged. 3. Inspect pivot bolt for free movement in assembly housing. Replace assembly if seized or excessive looseness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal > Page 2240 Timing Belt Tensioner: Service and Repair Engine Timing Tensioner - Installation Tensioner Pulley Assembly TENSIONER PULLEY ASSEMBLY 1. Install the timing belt tensioner pulley (1) assembly. Tighten the pivot bolt (2) to 61 Nm (45 ft. lbs.). 2. Install the timing belt, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Installation. Tensioner TENSIONER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal > Page 2241 1. For timing belt tensioner installation procedure, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations TIMING BELT CAUTION: The 3.5L is NOT a freewheeling engine. Therefore, the valve train rocker assemblies must be removed before attempting to rotate either crankshaft or camshafts independently of each other. CAUTION: If camshafts have moved from the timing marks, always rotate camshaft towards the direction nearest to the timing marks (DO NOT TURN CAMSHAFTS A FULL REVOLUTION OR DAMAGE to valves and/or pistons could result). TIMING GEAR ALIGNMENT 1. Align the crankshaft sprocket (10) with the TDC mark (9) on the oil pump cover. 2. Align the camshaft sprockets (2, 7) timing reference marks (1, 8) with the marks on the rear cover. 3. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket and maintain tension on the belt as it is positioned around the tensioner pulley (11). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Belt Cover -M6 Bolts.............................................................................................................................................. .....................................................12 Nm (105 in.lbs.) -M8 Bolts.......................................................... .........................................................................................................................................28 Nm (250 in.lbs.) -M10 Bolts................................................................................................................................. ...................................................................54 Nm (40 ft.lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal Timing Cover: Service and Repair Engine Timing Cover(s) - Removal Front REMOVAL 1. Perform fuel pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 2. Disconnect negative battery cable. 3. Raise the vehicle. 4. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 5. Remove accessory drive belt tensioner. 6. Remove bolts for power steering pump. Reposition power steering pump aside. 7. Remove crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2250 8. Remove the lower front timing belt cover fasteners. 9. Lower the vehicle. 10. Support the engine with a floor jack. 11. Remove the front engine mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator Removal. 12. Disconnect the fuel supply line at the fuel rail. 13. Remove the upper timing belt cover bolts and remove front timing belt cover See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Rear REMOVAL 1. Perform fuel pressure release procedure. See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 2. Disconnect the negative battery cable. 3. Remove timing belt, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal. 4. Remove camshaft sprockets, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2251 5. Remove rear timing belt cover bolts. 6. Remove the rear cover. NOTE: The rear timing belt cover has O-rings to seal the water pump passages to cylinder block. Do not reuse the O-rings. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2252 Timing Cover: Service and Repair Engine Timing Cover(s) - Installation Front INSTALLATION NOTE: The timing cover bolts and both holes to the engine block must be thoroughly cleaned and free of oil residue before assembly. IN ADDITION, add thread sealant to the timing cover bolts that mount to the oil pump. See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 1. Install front timing belt cover. 2. Install the upper engine mount See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator Installation. 3. Connect fuel supply line at fuel rail. 4. Raise the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2253 5. Install power steering pump fasteners. Tighten bolts to 23 Nm (200 lbs. in.). 6. Install crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Installation. 7. Install accessory drive belt tensioner. Torque fastener to 28 Nm (250 in. lbs.). 8. Install accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 9. Lower the vehicle. 10. Connect negative battery cable. Rear INSTALLATION 1. Clean rear timing belt cover O-ring sealing surfaces and grooves. Lubricate new O-rings with Mopar(R) Dielectric Grease or equivalent to facilitate assembly. 2. Position NEW O-rings on cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2254 3. Install rear timing belt cover. Tighten bolts to the following specified torque: - M10-54 Nm (40 ft. lbs.) - M8-28 Nm (20 ft. lbs.) - M6-12 Nm (105 in. lbs.) 4. Install camshaft sprockets, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Installation. 5. Install timing belt, See: Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Fuel Flow Leakdown Less than 10 psi in 5 minutes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. FUEL PUMP OPERATION 1. Ignition on, engine not running. 2. With a scan tool, actuate the Fuel System test. NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly with no excessive noise. If the pump has excessive noise such as grinding, the pump should be replaced. CAUTION: Stop All Actuations. Does the Fuel Pump sound to be operate normally? Yes - Go to 2 No - Go to 7 2. FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge. 3. Ignition on, engine not running. 4. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Choose a conclusion that best matches your fuel pressure reading. Below Specification - Go to 3 Within Specification - Test Complete. Above Specification - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2261 Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special tool #6539 (5/16") or #6631(3/8") fuel line adapter and the fuel pressure gauge between the fuel supply line and the fuel pump module. 4. Ignition on, engine not running. 5. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Is the fuel pressure within specification now? Yes - Repair/replace fuel supply line as necessary. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. CHECKING FUEL TANK SIPHON HOSE AND FUEL LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the Fuel Pump Module and the Fuel Tank Module. 3. Inspect the following fuel components: Fuel line and siphon hose between the Fuel Pump Module and the Fuel Tank Module. Look for disconnected and/or damaged lines or hoses. - Fuel Pressure Regulator not properly seated in the module. Were the above items in good working condition? Yes - Go to 6 No - Repair or replace as necessary. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. CHECKING THE FUEL PUMP INLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2262 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Inlet and the bottom of the fuel tank for debris that could cause the fuel pump inlet to be plugged. Is the Fuel Pump Inlet plugged? Yes - Repair/Replace as necessary. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP MOTOR GROUND CIRCUIT 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light to battery voltage, probe the Fuel Pump Motor Ground circuit in the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Does the test light illuminate brightly. Yes - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Motor Ground circuit. - Perform the PCM Verification TestSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2263 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2264 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2265 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2266 Fuel Pressure: Testing and Inspection Fuel Delivery System Output - Flow Test FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure. - Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. - Use extreme caution when connecting and disconnecting fuel lines. Considerable fuel leakage may occur when servicing the fuel system. Wear protective eyewear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair or replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester 8978A. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2267 Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly 8978A-1 Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: - Open the Fuel System Isolation Valve (1). - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2268 - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 1. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. 2. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa ± 34 kPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 kPa ± 34 kPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Ignition on, engine not running. 2. With the scan tool, actuate the fuel pump. 3. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. 4. Turn the ignition off. 5. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. Does the amount of fuel in the reservoir meet or exceed the specification? Yes - Test complete. No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Disengage the air filter housing clips (1). 2. Slide the air filter housing cover (2) forward slightly to disengage tabs from the bottom of the air filter housing. 3. Remove air cleaner element from air cleaner housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 2274 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install air filter element into the bottom half of the air filter housing. 2. Slide the air filter housing cover (2) rearward to engage the tabs into the bottom half of the air filter housing. 3. Reengage the air filter housing clips (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 2.4L The firing order is 1-3-4-2. 3.5L The firing order is 1-2-3-4-5-6. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal Spark Plug Tube: Service and Repair Removal REMOVAL 1. Remove cylinder head cover(s). See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal 2. Using suitable locking pliers, remove the tube (1) from the cylinder head and discard tube. 3. Clean area around spark plug with Mopar(R) Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal > Page 2287 Spark Plug Tube: Service and Repair Installation INSTALLATION 1. Apply Mopar(R) Stud and Bearing Mount to a new tube (1) approximately 1 mm (0.039 in.) from the end of tube, in a 3 mm (0.118 in.) wide area. 2. Install sealer end of tube (1) into the cylinder head. Then carefully install the tube (1) using a hardwood block and mallet. Install the tube (1) until it is seated into the bottom of the bore. 3. For spark plug tube (1) seal replacement, See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 4. Install cylinder head cover(s). See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation INSTALLATION) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Ratio .............................................................................................................................. ............................................................................ 10:1 Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2291 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the TIPM. 5. Install a suitable compression test gauge into the number 1 spark plug hole in cylinder head. 6. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP 2.4L Engine Bolts-Water Pump Mounting................................................................................................................. .......................................................24 Nm (18 ft. lbs) Bolts-Water Pump Inlet Tube to Block.............. ............................................................................................................................................12 Nm (9 ft. lbs) Bolts, Water Pump Inlet Tube to water pump housing.................................................................................................................................24 Nm (18 ft. lbs) Bolts, Water Pump to Water Pump Adapter........................................................................ .........................................................................22 Nm (16 ft. lbs) Bolts, Water Pump Pulley to Water Pump.................................................................................................................................................... .9 Nm (80 in. lbs) 3.5L Engine Bolts - Water Pump ............................................................................................................................. ........................................ 12 Nm (9 ft.lb., 106 in. lb.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Water Pump - Coolant Air Evacuation COOLANT AIR EVACUATION Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components. NOTE: To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. NOTE: The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system. NOTE: For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor). 1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps. 2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank. 3. Attach the adapter cone (2) to the vacuum gauge (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2297 4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1). 5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly. 6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1). 7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum. 8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse. 9. Close the vacuum generator/venturi ball valve. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2298 10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly. 11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. 12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system. 13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2). 14. Open the suction hose's ball valve to begin refilling the cooling system. 15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached. 16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly. 17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank. 18. With heater control unit in the HEAT position, operate engine with container cap in place. 19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container. 20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period. 21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap. Water Pump - Cleaning CLEANING Clean gasket mating surfaces as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2299 Water Pump: Removal and Replacement Water Pump - Removal 3.5L ENGINE NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. 1. Drain cooling system See: Cooling System/Service and Repair. 2. Remove engine timing belt See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Removal. 3. Remove water pump mounting bolts. Note position of longer bolt for proper re-installation. 4. Remove water pump body from engine. 5. Clean water pump mounting surface. Water Pump - Disassembly WATER PUMP - GAS ENGINE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2300 1. Remove the water pump assembly from the vehicle.See: Water Pump - Removal 2. Discard the water pump outlet gasket (7). 3. Remove the three bolts (1) attaching the water pump pulley (2) to the water pump (4). 4. Remove the water pump pulley (2). 5. Remove the five bolts (3) attaching the water pump (4) to the water pump adapter (6). 6. Remove and discard the gasket (8). 7. Remove the water pump (4) and inspect carefully for any damage. Water Pump - Assembly WATER PUMP - GAS ENGINE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2301 1. Throughly clean all gasket mating surfaces before assembling. 2. Inspect water pump and components for any damage. 3. Using bolts (3), install the water pump (4) and gasket (8) to the water pump adapter (6). Tighten the bolts (3) to 22 N-m (16 lbs. ft.) 4. Using bolts (1), install the water pump pulley (2) to the water pump (4). Tighten the bolts (1) to 9 N-m (80 lbs. in.) 5. Using bolts (5), install the water pump assembly and gasket to the engine block. Tighten the bolts to 24 Nm (18 lbs. ft.).See: Water Pump Installation 6. Start the engine and check for leaks.See: Cooling System/Testing and Inspection Water Pump - Installation 3.5L ENGINE 1. Clean all O-ring surfaces on pump and cover. 2. Install new O-ring on water pump. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2302 3. Position water pump to engine. 4. Install mounting bolts and tighten to 12 Nm (105 in. lbs.). 5. Install timing belt See: Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Installation. 6. Evacuate air and refill cooling system. See: Procedures/Water Pump - Coolant Air Evacuation 7. Check cooling system for leaks. See: Cooling System/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2308 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Single or Dual Zone Climate Control System ................................................................................................................................................. 9.8 qts. (9.3 L) Three-Zone Climate Control System ............................................................................................................................................................. 12 qts. (11.4 L) Includes heater and coolant recovery bottle filled to MAX level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2311 Coolant: Fluid Type Specifications Coolant ...................................... Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description - Engine Coolant Coolant: Description and Operation Description - Engine Coolant ENGINE COOLANT GAS ENGINES WARNING: Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of propylene glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol based coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description - Engine Coolant > Page 2314 Coolant: Description and Operation Operation COOLANT Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 2315 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Check coolant concentration when any additional coolant is added to the system, or after a coolant drain, flush and refill. Use of a hydrometer or Refractometer Tool 8286, refractometer can be used to test coolant concentration. A hydrometer tests the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and the higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 tests the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufacturers use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and are not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Removal WATER INLET TUBE The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing. 1. Drain cooling system See: Service and Repair. 2. Remove the coolant adapter and secondary thermostat See: Thermostat/Service and Repair/Engine Coolant Thermostat - Removal. 3. Raise and support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal > Page 2320 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Installation WATER INLET TUBE 1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2. Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment. 5. Install secondary thermostat and coolant adapter See: Thermostat/Service and Repair/Engine Coolant Thermostat - Installation. 6. Tighten coolant tube nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system See: Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description - Pressure System Coolant Reservoir: Description and Operation Description - Pressure System PRESSURE SYSTEM The coolant pressure container consists of a pressure chamber and a overflow chamber. The coolant pressure container is mounted in the right side engine compartment. NOTE: Coolant will normally be in the pressure chamber side of the coolant bottle. The overflow chamber should normally be empty Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description - Pressure System > Page 2325 Coolant Reservoir: Description and Operation Description - Non-Pressure System NON-PRESSURE The coolant recovery system used on 2.4L engine consists of a coolant recovery container and an overflow hose that is connected to the radiator. The coolant recovery container is mounted in the right side engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description - Pressure System > Page 2326 Coolant Reservoir: Description and Operation Operation - Pressure System PRESSURE SYSTEM The pressure chamber keeps the coolant free of trapped air, provides a volume for expansion and contraction, and provides a convenient and safe method for checking and adjusting coolant level at atmospheric pressure. It also provides some reserve coolant to cover minor leaks, evaporation or boiling losses. The overflow chamber allows coolant recovery in case of an overheat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description - Pressure System > Page 2327 Coolant Reservoir: Description and Operation Operation - Non-Pressure System NON-PRESSURE SYSTEM This system works in conjunction with the pressure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air. It provides a volume for expansion and contraction, provides a convenient and safe method for checking coolant level, and adjusting level at atmospheric pressure without removing the pressure cap. It also provides some reserve coolant to cover minor leaks and evaporation or boiling losses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal Coolant Reservoir: Service and Repair Coolant Recovery Bottle - Removal Non-Pressure System NON-PRESSURE SYSTEM 1. Disconnect the over flow tube (2) from radiator nipple (3). 2. Remove coolant recovery container mounting bolts (1). 3. Remove coolant recovery container (5). Pressure System PRESSURE SYSTEM Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2330 1. Drain coolant below the coolant recovery container level See: Service and Repair. 2. Disconnect the return hose from coolant recover container (1). 3. Remove coolant recovery container mounting bolts (3). 4. Disconnect supply hose (2) from the bottom of the coolant recovery container (1). 5. Remove coolant recovery container (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2331 Coolant Reservoir: Service and Repair Coolant Recovery Bottle - Installation Non-Pressure System NON-PRESSURE SYSTEM 1. Connect the overflow tube (2) to the radiator nipple (3). 2. Position coolant recovery container on mounting tab (4). Install mounting bolts (1). 3. Tighten mounting bolts to 10 Nm (89 in. lbs.). 4. Fill cooling system See: Service and Repair. Pressure System PRESSURIZED SYSTEM Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2332 1. Connect hose (3) to coolant recovery container (4). 2. Install coolant recovery container (4) in mounting position and install mounting bolts (1) Tighten bolts to 10 Nm (89 in. lbs.). 3. Connect return hose (2) to the coolant recovery container (4). 4. Fill cooling system See: Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 2337 Radiator Cooling Fan Control Module: Diagrams Connector - (FRONT END MODULE) 2 WAY FAN MODULE-RADIATOR COOLING - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Radiator Fan High Speed Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Radiator Fan High Speed Relay > Page 2360 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan Control Relay (In TIPM) 5 Way Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan Control Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RADIATOR FAN CONTROL - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan Control Relay (In TIPM) 5 Way > Page 2363 Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan High Speed Relay (Front End Module) 5 Way Connector - (FRONT END MODULE) 5 WAY RELAY-RADIATOR FAN HIGH - (FRONT END MODULE) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Locations > Page 2367 Radiator Cooling Fan Resistor: Diagrams Connector - (FRONT END MODULE) 2 WAY RESISTOR-RADIATOR FAN - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 2374 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2375 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2376 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2377 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description Heater Core: Description and Operation Front Heater Core - Description DESCRIPTION NOTE: LHD model shown. The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins and is positioned within the air distribution housing so that only the selected amount of air entering the housing passes through the heater core before it is distributed through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes (3). The heater core can only be serviced by removing the HVAC housing from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 2382 Heater Core: Description and Operation Front Heater Core - Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 2383 Heater Core: Description and Operation Rear Heater Core - Description DESCRIPTION The rear heater core (1) is located in the rear heater-A/C housing behind the right interior quarter trim panel. The rear heater core is a heat exchanger made of rows of tubes and fins (2). The heater core tubes (3) are permanently soldered to the heater core tank and are retained to the outboard side of the rear heater-A/C housing by use of an integral bracket (4) and screw. The rear heater-A/C housing must be removed from the vehicle to service the rear heater core. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 2384 Heater Core: Description and Operation Rear Heater Core - Operation OPERATION Engine coolant is circulated through heater hoses and tubes to the rear heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and the air directed through the heater core picks up the heat from the fins. The rear blend-air door allows control of the rear heater output air temperature by controlling the amount of air flowing through or around the rear heater core. The rear blower motor speed controls the volume of air flowing through the rear heater-A/C housing. The rear heater core cannot be repaired and must be replaced if inoperative, leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal Heater Core: Service and Repair Front Heater Core - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core. NOTE: LHD model with A/C shown. Heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench . 2. Remove the left side front floor duct See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Distribution Duct Removal. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (5). 4. Remove the screw (6) that secures the flange to the front of the HVAC housing and remove the flange. 5. On RHD models, remove the air distribution housing from the HVAC housing 6. Carefully pull the heater core (4) out of the driver side of the air distribution housing (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2387 Heater Core: Service and Repair Front Heater Core - Installation INSTALLATION NOTE: LHD model with A/C shown. 1. Carefully install the heater core (4) into the side of the air distribution housing (3). 2. On RHD models, install the air distribution housing onto the HVAC housing (5) . 3. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 4. Install the screw (6) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 5. Install the foam seal (1) onto the flange. 6. Install the left side front floor duct See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Distribution Duct - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Service and Repair . 7. Install the HVAC housing assembly . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2388 Heater Core: Service and Repair Rear Heater Core - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing and place it on a workbench See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Removal. 3. Remove the foam seal (2) from the flange (1) located at the bottom of the rear heater-A/C housing (3). If the foam seal is deformed or damaged, it must be replaced. 4. Remove the three screws (2) that secure the flange (1) to the bottom of the rear heater-A/C housing (3) and remove the flange. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2389 5. Disconnect the wire harness connector (3) from the rear blend door actuator (2) located on the outboard side of the rear heater-A/C housing (4). 6. Remove the two screws (1) that secure the rear blend door actuator to the rear heater-A/C housing and remove the actuator. 7. Disconnect the wire harness connector (1) from the rear mode door actuator (3) located on the outboard side of the rear heater-A/C distribution housing (2). 8. Remove the three metal retaining clips (4) that secure the rear distribution housing to the rear heater-A/C housing (5). 9. Release the five plastic retaining tabs (4) that secure the rear distribution housing and rear heater-A/C housing together and separate the housings. 10. Remove the screw (1) that secures the rear heater core tubes (3) to the outboard side of the rear heater-A/C housing (4). CAUTION: To prevent damage to the plastic evaporator tube bracket, carefully guide the heater core tubes past the bracket during removal of the heater core. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2390 11. Carefully pull the rear heater core (5) out of the top of the rear heater-A/C housing. Guide the heater core tubes past the plastic evaporator tube bracket (2). If the foam seals on the heater core are deformed or damaged, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2391 Heater Core: Service and Repair Rear Heater Core - Installation INSTALLATION CAUTION: To prevent damage to the plastic evaporator tube bracket, carefully guide the heater core tubes past the bracket during installation of the heater core. 1. Carefully install the rear heater core (5) into the rear heater-A/C housing (4). Guide the heater core tubes past the plastic evaporator tube bracket (2). Make sure that the foam seals are properly installed. 2. Install the screw (1) that secures the rear heater core tubes (3) to the outboard side of the rear heater-A/C housing. Tighten the screw to 1.2 Nm (10 in. lbs.). 3. Position the rear heater-A/C distribution housing (2) to the rear heater-A/C housing (5) and engage the five plastic retaining tabs (4). Make sure the retaining tabs are fully engaged. 4. Install the three metal retaining clips (6) that secure the rear distribution housing to the rear heater-A/C housing. 5. Connect the wire harness connector (1) to the rear mode door actuator (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2392 6. Position the rear blend door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear blend-air door pivot shaft (2). 7. Install the two screws (1) that secure the rear blend door actuator (2) to the rear heater-A/C housing (4). Tighten the screws to 1.2 Nm (10 in. lbs.). 8. Connect the wire harness connector (3) to the rear blend door actuator. 9. Position the flange (1) to the bottom of the rear heater-A/C housing (3) and install the three retaining screws (2). Tighten the screws to 1.2 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2393 10. Install the foam seal (2) onto the flange (1) at the bottom of the rear heater-A/C housing (3). Make sure that the foam seal is properly installed. 11. Install the rear heater-A/C housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 12. Reconnect the negative battery cable. 13. If the rear heater core is being replaced, flush the cooling system See: Service and Repair. 14. Refill the engine cooling system See: Service and Repair. 15. Evacuate and charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Removal Radiator Drain Plug: Service and Repair Removal DRAINCOCK CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock. NOTE: It is not necessary to remove draincock during a routine coolant drain. 1. Remove belly pan (if equipped). 2. Drain the cooling system See: Service and Repair. 3. Open the draincock (2) by turning it counterclockwise until it stops. 4. Turn the draincock (2) back (clockwise) 1/8 turn. 5. Pull the draincock (2) from the radiator tank (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Removal > Page 2399 Radiator Drain Plug: Service and Repair Installation DRAINCOCK 1. Align draincock (2) stem to radiator tank (1) opening. 2. Push draincock (2) into the radiator tank (1) opening. 3. Tighten the draincock (2) by turning clockwise until it stops. 4. Fill the cooling system See: Service and Repair. 5. Install belly pan (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Radiator Cap - Description Radiator Cap: Description and Operation Radiator Cap - Description DESCRIPTION The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97-124 kPa (14-18 psi). There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant reserve/recovery system container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Radiator Cap - Description > Page 2404 Radiator Cap: Description and Operation Radiator Cap - Operation OPERATION The pressure cap allows the cooling system to operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point; this allows increased radiator cooling capacity. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the cooling system from the reserve container. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Pressure Cap Radiator Cap: Testing and Inspection Radiator Pressure Cap RADIATOR PRESSURE CAP TESTING CAUTION: Vehicles equipped with 2.4L engines use a different pressure cap than vehicles equipped with 2.7L engines. The pressure caps are NOT interchangeable. Verify proper pressure cap part number. Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap. CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. If the pressure cap tests properly while positioned on Cooling System Tester but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Pressure Cap > Page 2407 Radiator Cap: Testing and Inspection Pressure Relief Test PRESSURE RELIEF TESTING WARNING: The warning words "DO NOT OPEN HOT" on the pressure cap is a safety precaution. When hot, the cooling system builds up pressure. To prevent scalding or other injury, the pressure cap should not be removed while the system is hot and/or under pressure. CAUTION: Vehicles equipped with 2.4L engines use a different pressure cap than vehicles equipped with 2.7L engines. The pressure caps are NOT interchangeable. Verify proper pressure cap part number. The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at the filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69-124 kPa (10-18 psi), and hold pressure at 55 kPa (8 psi) minimum. There is no need to remove the pressure cap at any time except for the following purposes: - Check and adjust coolant freeze point - Refill system with new coolant - Conducting service procedures - Checking for leaks WARNING: If vehicle has been run recently, wait 15 minutes before removing cap. Place a shop towel over the cap, and without pushing down, rotate it counterclockwise to the first stop. Allow fluids to escape through the overflow tube. When the system stops pushing coolant and steam into the coolant recovery tank and pressure drops, push down on the cap and remove it completely. Squeezing the radiator inlet hose with a shop towel (to check pressure) before and after turning to the first stop is recommended. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Radiator Cap - Cleaning Radiator Cap: Service and Repair Radiator Cap - Cleaning CLEANING Use only a mild soap to clean the pressure cap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Radiator Cap - Cleaning > Page 2410 Radiator Cap: Service and Repair Radiator Cap - Inspection INSPECTION Hold the cap in your hand, right side up. The vent valve at the bottom of the cap should fall open. Turn the cap upside down. The vent valve should close. Replace the cap for any of the following conditions: - Rubber gasket has swollen, preventing the valve from opening. - Any light can be seen between the vent valve and the rubber gasket (with cap upside down). - Gasket on the bottom of the cap shows noticeable thinning. - Cap has been through more than one engine overheat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 2415 Radiator Cooling Fan Control Module: Diagrams Connector - (FRONT END MODULE) 2 WAY FAN MODULE-RADIATOR COOLING - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Radiator Fan High Speed Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Radiator Fan High Speed Relay > Page 2420 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan Control Relay (In TIPM) 5 Way Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan Control Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RADIATOR FAN CONTROL - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan Control Relay (In TIPM) 5 Way > Page 2423 Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan High Speed Relay (Front End Module) 5 Way Connector - (FRONT END MODULE) 5 WAY RELAY-RADIATOR FAN HIGH - (FRONT END MODULE) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 2431 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2432 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2433 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2434 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Engine Coolant Thermostat - Description Thermostat: Description and Operation Engine Coolant Thermostat - Description 3.5L The thermostat is located on the lower left side of engine, near the front. The thermostat is on the inlet side of the water pump. It has an air bleed located in the thermostat flange. The air bleed allows internal trapped air during cooling system filling to be released. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Engine Coolant Thermostat - Description > Page 2439 Thermostat: Description and Operation Engine Coolant Thermostat - Operation OPERATION The engine cooling thermostat is a wax pellet driven, reverse poppet choke type. The thermostat is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). The thermostat also will automatically reach wide open so it will not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2440 Thermostat: Testing and Inspection ENGINE COOLANT THERMOSTAT TESTING The thermostat is operated by a wax filled container (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. The thermostat that opens too soon type failure mode is included in the on-board diagnosis. The check engine light will be lit by an open too soon condition. If it has failed open, a Diagnostic Trouble Code (DTC) will be set. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. For other probable causes, See: Testing and Inspection. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal Thermostat: Service and Repair Engine Coolant Thermostat - Removal 3.5L ENGINE WARNING: Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur. 1. Disconnect negative battery cable. 2. Drain cooling system See: Service and Repair. 3. Remove engine cover. 4. Disconnect radiator upper hose from thermostat housing. 5. Remove thermostat housing bolts. 6. Remove housing, thermostat, and gasket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal > Page 2443 Thermostat: Service and Repair Engine Coolant Thermostat - Installation 3.5L ENGINE 1. Clean gasket sealing surfaces. 2. Install thermostat and gasket into thermostat housing. For ease of installation, install bolts in housing for thermostat and gasket retention. 3. Install thermostat and housing to Intake manifold. Tighten bolts to 12 Nm (105 in. lbs.). 4. Connect radiator hoses and install hose clamp. 5. Install engine cover. 6. Refill cooling system See: Service and Repair. 7. Connect negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Coolant Outlet Housing - Removal Thermostat Housing: Service and Repair Coolant Outlet Housing - Removal REMOVAL WARNING: Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur. 1. Drain cooling system See: Service and Repair 2. Disconnect engine coolant temperature sensor connector. 3. Disconnect hoses at coolant outlet connector. 4. Remove bolts attaching coolant outlet connector. 5. Remove coolant outlet connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Coolant Outlet Housing - Removal > Page 2448 Thermostat Housing: Service and Repair Coolant Outlet Housing - Installation INSTALLATION 1. Clean sealing surfaces. Inspect gaskets for tears and cuts. Replace as necessary. 2. Install coolant outlet connector and tighten bolts to 12 Nm (105 in. lbs.). 3. Connect hoses at coolant outlet connector. 4. Connect engine coolant temperature sensor connector. 5. Fill cooling system See: Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP 2.4L Engine Bolts-Water Pump Mounting................................................................................................................. .......................................................24 Nm (18 ft. lbs) Bolts-Water Pump Inlet Tube to Block.............. ............................................................................................................................................12 Nm (9 ft. lbs) Bolts, Water Pump Inlet Tube to water pump housing.................................................................................................................................24 Nm (18 ft. lbs) Bolts, Water Pump to Water Pump Adapter........................................................................ .........................................................................22 Nm (16 ft. lbs) Bolts, Water Pump Pulley to Water Pump.................................................................................................................................................... .9 Nm (80 in. lbs) 3.5L Engine Bolts - Water Pump ............................................................................................................................. ........................................ 12 Nm (9 ft.lb., 106 in. lb.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Water Pump - Coolant Air Evacuation COOLANT AIR EVACUATION Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components. NOTE: To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. NOTE: The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system. NOTE: For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor). 1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps. 2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank. 3. Attach the adapter cone (2) to the vacuum gauge (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2454 4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1). 5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly. 6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1). 7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum. 8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse. 9. Close the vacuum generator/venturi ball valve. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2455 10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly. 11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. 12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system. 13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2). 14. Open the suction hose's ball valve to begin refilling the cooling system. 15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached. 16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly. 17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank. 18. With heater control unit in the HEAT position, operate engine with container cap in place. 19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container. 20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period. 21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap. Water Pump - Cleaning CLEANING Clean gasket mating surfaces as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2456 Water Pump: Removal and Replacement Water Pump - Removal 3.5L ENGINE NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. 1. Drain cooling system See: Service and Repair. 2. Remove engine timing belt See: Engine/Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets - Removal. 3. Remove water pump mounting bolts. Note position of longer bolt for proper re-installation. 4. Remove water pump body from engine. 5. Clean water pump mounting surface. Water Pump - Disassembly WATER PUMP - GAS ENGINE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2457 1. Remove the water pump assembly from the vehicle.See: Water Pump - Removal 2. Discard the water pump outlet gasket (7). 3. Remove the three bolts (1) attaching the water pump pulley (2) to the water pump (4). 4. Remove the water pump pulley (2). 5. Remove the five bolts (3) attaching the water pump (4) to the water pump adapter (6). 6. Remove and discard the gasket (8). 7. Remove the water pump (4) and inspect carefully for any damage. Water Pump - Assembly WATER PUMP - GAS ENGINE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2458 1. Throughly clean all gasket mating surfaces before assembling. 2. Inspect water pump and components for any damage. 3. Using bolts (3), install the water pump (4) and gasket (8) to the water pump adapter (6). Tighten the bolts (3) to 22 N-m (16 lbs. ft.) 4. Using bolts (1), install the water pump pulley (2) to the water pump (4). Tighten the bolts (1) to 9 N-m (80 lbs. in.) 5. Using bolts (5), install the water pump assembly and gasket to the engine block. Tighten the bolts to 24 Nm (18 lbs. ft.).See: Water Pump Installation 6. Start the engine and check for leaks.See: Testing and Inspection Water Pump - Installation 3.5L ENGINE 1. Clean all O-ring surfaces on pump and cover. 2. Install new O-ring on water pump. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2459 3. Position water pump to engine. 4. Install mounting bolts and tighten to 12 Nm (105 in. lbs.). 5. Install timing belt See: Engine/Timing Components/Timing Belt/Service and Repair/Removal and Replacement/Timing Belt & Sprockets Installation. 6. Evacuate air and refill cooling system. See: Procedures/Water Pump - Coolant Air Evacuation 7. Check cooling system for leaks. See: Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 2466 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications EXHAUST MANIFOLD Exhaust Manifold to Cylinder Head-Bolts............................................................................................. ....................................................23 Nm (200 in.lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures INSPECTION 1. Inspect exhaust maniverters for damage or cracks. 2. Check maniverter mounting surface flatness. 3. Inspect the exhaust manifold gasket for obvious discoloration or distortion. 4. Check distortion of the cylinder head mounting surface with a straightedge and thickness gauge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2472 Exhaust Manifold: Removal and Replacement Front Exhaust Maniverter REMOVAL - FRONT EXHAUST MANIVERTER 1. Disconnect and isolate the negative battery cable. 2. Remove the fasteners (1), and remove the upper heat shield (2). 3. Loosen the oil level indicator tube retaining bolt (3) and position the dipstick tube (2) aside. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2473 4. Remove the 12 belly pan fasteners (1) and remove the belly pan (2). 5. Remove the left maniverter-to-crossunder pipe fasteners (1). 6. Disconnect the harness connector (1) and remove the front lower maniverter oxygen sensor (2). 7. Disconnect the harness connector (3) and remove the front upper maniverter oxygen sensor (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2474 8. Remove the maniverter retaining bolts (1), the maniverter (2), and gasket (3). Rear Exhaust Maniverter REMOVAL - REAR EXHAUST MANIVERTER, AWD 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance. 3. Remove twelve belly pan fasteners (1) and remove the belly pan (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2475 4. Remove the right front tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal 5. Remove the exhaust extension pipe (1) See: Exhaust Pipe/Service and Repair/Exhaust Pipe Removal. 6. Remove the exhaust crossunder pipe (3) See: Exhaust Pipe/Service and Repair/Exhaust Crossunder Pipe - Removal 7. Disconnect harness connectors (1) and (3). Remove the right maniverter downstream (2) and upstream (4) oxygen sensors See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Removal 8. Remove heat shield retainers (1), (2), and (3) and remove the upper heat shield (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2476 9. Remove the right half shaft and intermediate shaft (4) See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Intermediate Shaft/Removal 10. Remove the maniverter retaining bolts (5). 11. Reposition the maniverter to allow removal of the lower maniverter heatshield (2). 12. Remove the lower maniverter heat shield retainers (1) and remove the lower maniverter heat shield (2). 13. Remove the maniverter and gasket from the vehicle. Front Exhaust Maniverter INSTALLATION - FRONT EXHAUST MANIVERTER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2477 1. Position the maniverter (2) and gasket (3). Install the retaining bolts (1). Tighten bolts starting at the center working outward to 23 N.m (200 in. lbs.). 2. Install the upper heat shield (2), and torque nuts (1) to 12 Nm (105 in.lbs). 3. Install the oil level indicator tube (2) and the retaining bolt (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2478 4. Install the left upstream oxygen sensor (4) and connect the harness connector (3). 5. Install the left downstream oxygen sensor (2) and connect the harness connector (1). 6. Install the left maniverter cross under pipe retaining bolts (1). Tighten bolts to 31 N.m (275 in. lbs.). 7. Install the belly pan (2) and the 12 belly pan fasteners (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2479 8. Connect the negative battery cable See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection. Rear Exhaust Maniverter INSTALLATION - REAR EXHAUST MANIVERTER, AWD 1. Clean the right maniverter gasket sealing surfaces with an appropriate tool See: Engine/Service and Repair/Procedures. 2. Place the right maniverter in the engine compartment and position to allow installation of the maniverter lower heatshield (2). 3. Install the right maniverter lower heat shield (2) with heat shield retainers (1). 4. Install the right maniverter (6) and gasket (8) with retaining bolts (5). Tighten the bolts starting at the center working outward to 23 Nm (200 in. lbs.). 5. Install the right maniverter upper heat shield (4) with heat shield retainers (1), (2), and (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2480 6. Install the intermediate shaft (4) and right half shaft See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Intermediate Shaft/Installation 7. Install the right maniverter upstream (4) and downstream (2) oxygen sensors and reconnect the harness connectors (1) and (3) See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Installation. 8. Install the exhaust crossunder pipe (3) See: Exhaust Pipe/Service and Repair/Exhaust Crossunder Pipe - Installation 9. Install the exhaust extension pipe (1) See: Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2481 10. Install the right front tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation 11. Install the belly pan (2) and the twelve belly pan fasteners (1). 12. Lower the vehicle. 13. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal Exhaust Pipe: Service and Repair Exhaust Pipe - Removal 3.5L WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operation time. 1. Raise vehicle on hoist. 2. Apply penetrating oil to exhaust pipe band clamp, and fasteners (2). 3. Loosen band clamp for resonator/pipe assembly. 4. Remove exhaust pipe mounting nuts (2) at cross under pipe (3). 5. Remove exhaust pipe (1) and gasket from vehicle. 6. Discard band clamp. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2486 Exhaust Pipe: Service and Repair Exhaust Pipe - Installation 3.5L 1. Position exhaust pipe (1) into muffler/resonator assembly. 2. Position exhaust pipe onto cross over pipe. 3. Install exhaust pipe (1) to cross over pipe nuts. Tighten to 28 Nm (250 in. lbs.). 4. Align exhaust pipe (1) and resonator/muffler pipe assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners attaching exhaust pipe (1) to cross-under pipe (3) to 28 Nm (21 ft. lbs.). 5. Install new band clamp. Tighten band clamp to 54 Nm (40 ft. lbs.). 6. Lower vehicle. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.See: Testing and Inspection/Component Tests and General Diagnostics 8. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2487 Exhaust Pipe: Service and Repair Exhaust Crossunder Pipe - Removal 3.5L ENGINE 1. Raise vehicle on hoist. 2. Remove the fasteners (1) and remove the belly pan (2). 3. Disconnect exhaust system pipe (1) from cross under pipe. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2488 4. Remove cross-under pipe bracket to cross under pipe bolt (1). 5. Remove cross under to front maniverter bolts and nuts (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2489 6. Remove cross under to rear maniverter bolts (5) and nuts (3). 7. Remove cross under pipe. 8. If necessary, remove cross under transmission bracket (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2490 Exhaust Pipe: Service and Repair Exhaust Crossunder Pipe - Installation 3.5L ENGINE 1. If removed, install bracket (2). Tighten bolts (1) to 29 Nm (21 ft. lb.). 2. Position cross under pipe. 3. Install cross under to rear maniverter bolts (5) and nuts (3). Tighten to 27 Nm (20 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2491 4. Install cross under to front maniverter bolts and nuts. Tighten to 27 Nm (20 ft. lbs.). 5. Install cross under pipe bracket to cross under pipe bolt (1). Tighten to 27 Nm (20 ft. lbs.). 6. Install exhaust system pipe. Tighten flange nuts to 28 Nm (21 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 2492 7. Install belly pan (2) and fasteners (1). 8. Lower vehicle. 9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.See: Testing and Inspection/Component Tests and General Diagnostics 10. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2497 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Description Heat Shield: Description and Operation Description DESCRIPTION The exhaust system heat shields are attached to the under body of the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Description > Page 2502 Heat Shield: Description and Operation Operation OPERATION Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed near the catalytic converter. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on vehicles so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal MUFFLER NOTE: Band clamps (3) are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off the exhaust pipe. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used. 1. Raise vehicle on hoist. 2. Apply penetrating oil to band clamp (3). 3. Remove band clamp (3). 4. Remove ground strap from muffler (2). CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone based lubricant spray may be Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 2507 used to assist removal/installation of isolators. DO NOT use a petroleum based lubricant on the isolators, as damage to the rubber material can occur. 5. Remove support isolators from muffler supports. 6. Remove the one muffler/resonator assembly. . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 2508 Muffler: Service and Repair Installation MUFFLER NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components. 1. Position muffler/resonator assembly (2) onto exhaust pipe. 2. Install support isolators. 3. Align muffler and resonator assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. 4. Install new band clamp (3). Tighten to 54 Nm (40 ft. lbs.). 5. Connect ground strap to muffler (2). 6. Lower vehicle. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.See: Testing and Inspection/Component Tests and General Diagnostics 8. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2514 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 2519 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2531 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2532 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2533 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2534 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2535 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2536 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2537 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2538 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2539 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2540 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2541 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: Customer Interest Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 2551 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 2556 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: Customer Interest Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 2561 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 2566 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: Customer Interest Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 2571 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 2577 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 2582 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 2587 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 2592 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2597 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2598 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2599 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2600 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2601 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2602 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2603 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2604 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2605 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2606 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2607 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering Power Steering Whine > Page 2616 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 2622 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 2627 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 2632 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 2637 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering Power Steering Whine > Page 2642 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2648 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2649 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2650 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2651 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2652 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2653 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2654 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2655 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2656 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2657 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2658 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 2665 Engine Control Module: Locations Powertrain Control Module (NGC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 2666 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Connector C1 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2669 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2670 Engine Control Module: Diagrams Powertrain Control Module C2 (NGC) (Engine) 38 Way Connector C2 (NGC) - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (ENGINE) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2671 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2672 Engine Control Module: Diagrams Powertrain Control Module C3 (NGC) (Headlamp And Dash) 38 Way Connector C3 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2673 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2674 Engine Control Module: Diagrams Powertrain Control Module C4 (NGC) (Transmission) 38 Way Connector C4 (NGC) - (TRANSMISSION) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (TRANSMISSION) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 2675 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - ASD/Main Relay - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback (if equipped) - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Inlet Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral (from trans range sensor) - Power Steering Pressure Switch - Proportional Purge Sense - CAN C Bus - Speed Control - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Data Link Connector (CAN C Bus) - Double Start Override - EGR Solenoid (if equipped) - Fuel Injectors - Generator Field - High Speed Fan Relay - Ignition Coils - Natural Vacuum Leak Detection - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - 5 Volt Output Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation and EGR if equipped. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2678 rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Manifold Absolute Pressure - Engine Speed (crankshaft position sensor) - Battery Voltage - Inlet Air Temperature Sensor - Engine Coolant Temperature - Exhaust Gas Oxygen Content (heated oxygen sensors) - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed (from Transmission Control Module) The PCM adjusts ignition timing based on the following inputs. - Inlet Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral (from trans range sensor) - Transaxle Gear Engagement - Throttle Position The camshaft and crankshaft signals are sent to the Powertrain Control Module (PCM). If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the fuel pump. When deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. The PCM contains a voltage converter that changes battery voltage to a regulated 5.0 volts. The 5.0 volts power the camshaft position sensor, and crankshaft position sensor. The PCM also provides a regulated 5.0 volts supply for the, manifold absolute pressure sensor, throttle position sensor and EGR (if equipped). The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the scan tool to change the mileage in the PCM. Refer to the appropriate Powertrain Diagnostic Manual and the scan tool. If equipped with SKREEM, must use SKREEM function to program VIN number in new PCM. TRANSMISSION CONTROL CVI CALCULATION An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2679 Gear ratios can be determined by using the scan tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES The PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2680 Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Replacement PCM REPLACEMENT DESCRIPTION Use the scan tool to reprogram the new pcm with the vehicle's original identification number (vin) and the vehicle's original mileage. If this step is not done a Diagnostic Trouble Code (DTC) may be set. PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side of relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded via the mounting screws AND bracket to the chassis, separately from the ground pins. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2681 Engine Control Module: Description and Operation Powertrain Control Module - Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pullup resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2682 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2683 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. CHECKING THE PCM FUSED B+ CIRCUITS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2684 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Using a 12 volt test light connected to ground, check the PCM power supply circuits. 2. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 4. No - Repair the PCM power supply circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 4. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM (F202) and (F1) Fused Ignition circuits. 3. Wiggle test each circuit during the test to check for an intermittent open or short in the circuit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2685 NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Go to 5. No - Repair the open or short in the Fused Ignition Switch circuits. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition Switch circuits. 3. Check each circuit with the ignition off, ignition on, engine not running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the PCM Fused Ignition Switch circuit(s) for as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. PCM/TCM Programming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2688 > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using wiTECH(TM) Diagnostic Application. Go To REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See SECTION 3 AUTHORIZED MODIFCATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2689 SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Aisin TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quick learn Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2690 If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2691 - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2692 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Quick learn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quick learn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFCATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2693 TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids', under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Module/Programming Order Replacement Guide MODULE/PROGRAMMING ORDER REPLACEMENT GUIDE Module Programming Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2694 MODULE PROGRAMMING The Wireless Ignition Node (WIN) controls the Vehicle Theft Security System (VTSS), Remote Keyless Entry (RKE). When a Powertrain Control Module (PCM) is in need of replacement, perform the following steps in order: NOTE: The PCM and the WIN should never be replaced at the same time. They should be replaced independently of each other. 1. If applicable, first replace the PCM with the original WIN still connected to the vehicle. 2. Using a scan tool program the new PCM. (This will ensure the transfer of the Secret Key data from the original WIN into the new PCM). 3. Replace the WIN, using the scan tool program the new WIN module. This will transfer the Secret Key data from the PCM into the new WIN. 4. With the scan tool reprogram the key FOBIK to the new WIN. 5. Ensure all the customer's keys have been programmed to the new module. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SECRET KEY TO THE WIN The secret key is an ID code that is unique to each WIN. This code is programmed and stored in the WIN, the PCM, and each ignition key transponder chip. When the PCM or WIN is replaced, it is necessary to program the Secret Key Code into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, WIN REPLACED, or TIPM REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE menu item as appropriate. NOTE: Programming the PCM or WIN is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour and then enter the correct PIN. Be certain that all accessories are turned OFF. Also, monitor the battery state and connect a battery charger if necessary. PCM/WIN PROGRAMMING When an PCM and the WIN are replaced at the same time, perform the following steps in order: 1. Program the new WIN. 2. Replace all ignition keys and program them to the new WIN. PROGRAMMING THE WIN CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. NOTE: Have a unique vehicle PIN readily available before running the routine CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 3. Select "ECU View." 4. Select "WIN". 5. Select "Miscellaneous Functions." 6. Select "WIN Replaced". 7. Enter the PIN when prompted. 8. Cycle ignition key after the successful routine completion. NOTE: If the PCM and the WIN are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new WIN. PROGRAMMING IGNITION KEYS TO THE WIN Each FOBIK has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the WIN, the module learns the transponder ID code and the transponder acquires the unique Secret Key ID code from the WIN. CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2695 4. Ignition key should be in RUN position. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "Program Ignition Keys or Key FOBs", Start 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned by the WIN. Once a key is learned by a WIN, that key has acquired the Secret Key for that WIN and cannot be transferred to any other WIN or vehicle. PROGRAMMING THE PCM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. 4. Ignition key should be in RUN position. CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "PCM Replaced". 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2696 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL - NGC CONTROLLER NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and the negative battery cable must be disconnected before unplugging the PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the 4 electrical connectors at the PCM. 3. Remove the 3 fasteners (1) holding the PCM to the bracket. Powertrain Control Module - Installation INSTALLATION - NGC CONTROLLER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2697 NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM to bracket with 3 fasteners (1). 2. Install and lock the 4 electrical connectors to the PCM. 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 4. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 2702 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 2703 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 2706 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 2712 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 2713 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 2716 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2722 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 2727 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 2732 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2733 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2734 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2737 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 2743 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2744 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2745 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2746 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2750 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2751 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2754 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 2759 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2764 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module Fuel Level Sensor: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 2769 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 2770 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 2771 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 2774 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 2777 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 2778 Fuel Level Sensor: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2781 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2782 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2783 1. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2784 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2785 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2786 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2787 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2788 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2789 Fuel Level Sensor: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2790 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2791 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2795 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2796 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (HEADLAMP AND DASH) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable. NOTE: Clean dirt from sensor area prior to removal from air box. 2. Disconnect the inlet air temperature sensor electrical connector (1). 3. Remove the inlet air temperature sensor (2) from the air box (3) by turning the sensor 1/4 turn in the counter - clockwise direction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 2799 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the inlet air temperature sensor (2) to the air box (3) by turning the sensor 1/4 turn in the clockwise direction. 2. Connect the inlet air temperature sensor electrical connector (1). 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2803 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2804 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2807 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2811 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2812 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-MANIFOLD ABSOLUTE PRESSURE (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2813 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. MAP SENSOR WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2814 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2815 - Go to 4 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2816 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 3.5L 1. Disconnect and isolate negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Rotate sensor. 4. Lift to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 2819 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 3.5L 1. Install sensor. 2. Rotate sensor into position. 3. Attach electrical connector (1) to sensor (2). 4. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 2824 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 2825 Oxygen Sensor: Locations Sensor - Oxygen 2/1 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 2826 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 2827 Oxygen Sensor: Locations Sensor - Oxygen 2/2 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 2828 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Gas) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 2831 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Gas) (Engine) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 2832 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 2833 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2834 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2835 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2836 Yes - Go to 4 - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2837 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove O2S (2) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (5). 6. Remove O2S (3) from catalytic converter (4). DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2840 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove the O2S (5) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (2). 6. Remove O2S (3) from catalytic converter (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2841 Oxygen Sensor: Service and Repair Installation 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (2). 3. Install the O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2842 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (5). 3. Install O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2846 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 2849 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 2850 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 2851 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 2852 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 2853 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 2859 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 2864 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2869 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 2874 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 2880 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2881 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2882 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2885 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2889 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2890 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2893 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations Ignition Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 2897 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 Ignition Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 Ignition Switch: Connector Views Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 2917 Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Operation OPERATION Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a spring-loaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY,""RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS) Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Operation. REMOTE KEYLESS ENTRY (RKE) The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Operation TIRE PRESSURE MONITORING (TPM) The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Operation. REMOTE START WITH/EXTENDED RANGE ANTENNA Further information concerning the Remote Start System. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Starting System/Description and Operation/Starting System - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI) The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. PARK SHIFT INTERLOCK The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 2918 Ignition Switch: Description and Operation Ignition Switch - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN). The WIN, along with the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch located on the face of the instrument panel just to the inboard side of the steering column. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. In addition to replacing a conventional keyed ignition switch, the WIN is an integrated electronic receiver that serves as the base station in the vehicle. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) RF communication. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged the entire WIN must be replaced See: Service and Repair/Wireless Ignition Node Receiver - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ignition Switch: Symptom Related Diagnostic Procedures FOBIK TRAPPED IN WIN The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 5. Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. 6. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. 7. Remove the lower WIN attaching screw (5). 8. Remove the lower WIN bracket attaching screw (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 2923 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 2924 Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Installation INSTALLATION NOTE: The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening. 2. Install the lower WIN bracket attaching screw (4). 3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 2925 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Install knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker Installation. 9. Connect negative battery cable. 10. If necessary, program the WIN, See: Computers and Control Systems/Testing and Inspection/Programming and Relearning. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2929 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2930 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2933 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Fuel Flow Leakdown Less than 10 psi in 5 minutes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. FUEL PUMP OPERATION 1. Ignition on, engine not running. 2. With a scan tool, actuate the Fuel System test. NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly with no excessive noise. If the pump has excessive noise such as grinding, the pump should be replaced. CAUTION: Stop All Actuations. Does the Fuel Pump sound to be operate normally? Yes - Go to 2 No - Go to 7 2. FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge. 3. Ignition on, engine not running. 4. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Choose a conclusion that best matches your fuel pressure reading. Below Specification - Go to 3 Within Specification - Test Complete. Above Specification - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2940 Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special tool #6539 (5/16") or #6631(3/8") fuel line adapter and the fuel pressure gauge between the fuel supply line and the fuel pump module. 4. Ignition on, engine not running. 5. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Is the fuel pressure within specification now? Yes - Repair/replace fuel supply line as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. CHECKING FUEL TANK SIPHON HOSE AND FUEL LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the Fuel Pump Module and the Fuel Tank Module. 3. Inspect the following fuel components: Fuel line and siphon hose between the Fuel Pump Module and the Fuel Tank Module. Look for disconnected and/or damaged lines or hoses. - Fuel Pressure Regulator not properly seated in the module. Were the above items in good working condition? Yes - Go to 6 No - Repair or replace as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. CHECKING THE FUEL PUMP INLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2941 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Inlet and the bottom of the fuel tank for debris that could cause the fuel pump inlet to be plugged. Is the Fuel Pump Inlet plugged? Yes - Repair/Replace as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP MOTOR GROUND CIRCUIT 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light to battery voltage, probe the Fuel Pump Motor Ground circuit in the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Does the test light illuminate brightly. Yes - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Motor Ground circuit. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2942 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2943 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2944 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2945 Fuel Pressure: Testing and Inspection Fuel Delivery System Output - Flow Test FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure. - Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. - Use extreme caution when connecting and disconnecting fuel lines. Considerable fuel leakage may occur when servicing the fuel system. Wear protective eyewear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair or replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester 8978A. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2946 Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly 8978A-1 Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: - Open the Fuel System Isolation Valve (1). - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2947 - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 1. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. 2. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa ± 34 kPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 kPa ± 34 kPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Ignition on, engine not running. 2. With the scan tool, actuate the fuel pump. 3. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. 4. Turn the ignition off. 5. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. Does the amount of fuel in the reservoir meet or exceed the specification? Yes - Test complete. No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Disengage the air filter housing clips (1). 2. Slide the air filter housing cover (2) forward slightly to disengage tabs from the bottom of the air filter housing. 3. Remove air cleaner element from air cleaner housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 2953 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install air filter element into the bottom half of the air filter housing. 2. Slide the air filter housing cover (2) rearward to engage the tabs into the bottom half of the air filter housing. 3. Reengage the air filter housing clips (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 2.4L The firing order is 1-3-4-2. 3.5L The firing order is 1-2-3-4-5-6. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal Spark Plug Tube: Service and Repair Removal REMOVAL 1. Remove cylinder head cover(s). See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal 2. Using suitable locking pliers, remove the tube (1) from the cylinder head and discard tube. 3. Clean area around spark plug with Mopar(R) Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal > Page 2966 Spark Plug Tube: Service and Repair Installation INSTALLATION 1. Apply Mopar(R) Stud and Bearing Mount to a new tube (1) approximately 1 mm (0.039 in.) from the end of tube, in a 3 mm (0.118 in.) wide area. 2. Install sealer end of tube (1) into the cylinder head. Then carefully install the tube (1) using a hardwood block and mallet. Install the tube (1) until it is seated into the bottom of the bore. 3. For spark plug tube (1) seal replacement, See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 4. Install cylinder head cover(s). See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation - INSTALLATION) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Ratio .............................................................................................................................. ............................................................................ 10:1 Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2970 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the TIPM. 5. Install a suitable compression test gauge into the number 1 spark plug hole in cylinder head. 6. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2975 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 2980 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2984 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2985 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (HEADLAMP AND DASH) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable. NOTE: Clean dirt from sensor area prior to removal from air box. 2. Disconnect the inlet air temperature sensor electrical connector (1). 3. Remove the inlet air temperature sensor (2) from the air box (3) by turning the sensor 1/4 turn in the counter - clockwise direction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 2988 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the inlet air temperature sensor (2) to the air box (3) by turning the sensor 1/4 turn in the clockwise direction. 2. Connect the inlet air temperature sensor electrical connector (1). 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 2993 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2994 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2995 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2998 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 3003 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 3009 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3010 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3011 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3012 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3016 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3017 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3020 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3024 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3025 Data Link Connector: Diagrams Connector - (INSTRUMENT PANEL) 16 WAY DATA LINK CONNECTOR - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector - Description Data Link Connector: Description and Operation Data Link Connector - Description DESCRIPTION The Data Link Connector (DLC) (2) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the lower instrument panel reinforcement, just forward of the instrument panel steering column opening cover (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector - Description > Page 3028 Data Link Connector: Description and Operation Data Link Connector - Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3037 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3038 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3039 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3040 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3041 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3042 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3043 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3044 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3045 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3046 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3047 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls PCM Update For Cruise Control Function Engine Control Module: Customer Interest Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls PCM Update For Cruise Control Function > Page 3057 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls MIL ON/DTC P2181 Is Stored In Memory > Page 3062 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls ECM Update For Over-Rev Condition Engine Control Module: Customer Interest Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls ECM Update For Over-Rev Condition > Page 3067 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 3072 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: Customer Interest Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 3077 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 3083 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 3088 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 3093 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 3098 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3103 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3104 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3105 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3106 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3107 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3108 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3109 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3110 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3111 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3112 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3113 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 3122 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 3128 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 3133 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 3138 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 3143 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 3148 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3154 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3155 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3156 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3157 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3158 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3159 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3160 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3161 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3162 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3163 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3164 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 3171 Engine Control Module: Locations Powertrain Control Module (NGC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 3172 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Connector C1 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3175 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3176 Engine Control Module: Diagrams Powertrain Control Module C2 (NGC) (Engine) 38 Way Connector C2 (NGC) - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (ENGINE) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3177 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3178 Engine Control Module: Diagrams Powertrain Control Module C3 (NGC) (Headlamp And Dash) 38 Way Connector C3 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3179 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3180 Engine Control Module: Diagrams Powertrain Control Module C4 (NGC) (Transmission) 38 Way Connector C4 (NGC) - (TRANSMISSION) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (TRANSMISSION) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3181 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - ASD/Main Relay - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback (if equipped) - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Inlet Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral (from trans range sensor) - Power Steering Pressure Switch - Proportional Purge Sense - CAN C Bus - Speed Control - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Data Link Connector (CAN C Bus) - Double Start Override - EGR Solenoid (if equipped) - Fuel Injectors - Generator Field - High Speed Fan Relay - Ignition Coils - Natural Vacuum Leak Detection - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - 5 Volt Output Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation and EGR if equipped. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3184 rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Manifold Absolute Pressure - Engine Speed (crankshaft position sensor) - Battery Voltage - Inlet Air Temperature Sensor - Engine Coolant Temperature - Exhaust Gas Oxygen Content (heated oxygen sensors) - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed (from Transmission Control Module) The PCM adjusts ignition timing based on the following inputs. - Inlet Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral (from trans range sensor) - Transaxle Gear Engagement - Throttle Position The camshaft and crankshaft signals are sent to the Powertrain Control Module (PCM). If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the fuel pump. When deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. The PCM contains a voltage converter that changes battery voltage to a regulated 5.0 volts. The 5.0 volts power the camshaft position sensor, and crankshaft position sensor. The PCM also provides a regulated 5.0 volts supply for the, manifold absolute pressure sensor, throttle position sensor and EGR (if equipped). The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the scan tool to change the mileage in the PCM. Refer to the appropriate Powertrain Diagnostic Manual and the scan tool. If equipped with SKREEM, must use SKREEM function to program VIN number in new PCM. TRANSMISSION CONTROL CVI CALCULATION An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3185 Gear ratios can be determined by using the scan tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES The PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3186 Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Replacement PCM REPLACEMENT DESCRIPTION Use the scan tool to reprogram the new pcm with the vehicle's original identification number (vin) and the vehicle's original mileage. If this step is not done a Diagnostic Trouble Code (DTC) may be set. PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side of relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded via the mounting screws AND bracket to the chassis, separately from the ground pins. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3187 Engine Control Module: Description and Operation Powertrain Control Module - Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pullup resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3188 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3189 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. CHECKING THE PCM FUSED B+ CIRCUITS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3190 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Using a 12 volt test light connected to ground, check the PCM power supply circuits. 2. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 4. No - Repair the PCM power supply circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 4. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM (F202) and (F1) Fused Ignition circuits. 3. Wiggle test each circuit during the test to check for an intermittent open or short in the circuit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3191 NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Go to 5. No - Repair the open or short in the Fused Ignition Switch circuits. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition Switch circuits. 3. Check each circuit with the ignition off, ignition on, engine not running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the PCM Fused Ignition Switch circuit(s) for as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. PCM/TCM Programming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3194 > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using wiTECH(TM) Diagnostic Application. Go To REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See SECTION 3 AUTHORIZED MODIFCATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3195 SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Aisin TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quick learn Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3196 If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3197 - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3198 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Quick learn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quick learn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFCATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3199 TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids', under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Module/Programming Order Replacement Guide MODULE/PROGRAMMING ORDER REPLACEMENT GUIDE Module Programming Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3200 MODULE PROGRAMMING The Wireless Ignition Node (WIN) controls the Vehicle Theft Security System (VTSS), Remote Keyless Entry (RKE). When a Powertrain Control Module (PCM) is in need of replacement, perform the following steps in order: NOTE: The PCM and the WIN should never be replaced at the same time. They should be replaced independently of each other. 1. If applicable, first replace the PCM with the original WIN still connected to the vehicle. 2. Using a scan tool program the new PCM. (This will ensure the transfer of the Secret Key data from the original WIN into the new PCM). 3. Replace the WIN, using the scan tool program the new WIN module. This will transfer the Secret Key data from the PCM into the new WIN. 4. With the scan tool reprogram the key FOBIK to the new WIN. 5. Ensure all the customer's keys have been programmed to the new module. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SECRET KEY TO THE WIN The secret key is an ID code that is unique to each WIN. This code is programmed and stored in the WIN, the PCM, and each ignition key transponder chip. When the PCM or WIN is replaced, it is necessary to program the Secret Key Code into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, WIN REPLACED, or TIPM REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE menu item as appropriate. NOTE: Programming the PCM or WIN is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour and then enter the correct PIN. Be certain that all accessories are turned OFF. Also, monitor the battery state and connect a battery charger if necessary. PCM/WIN PROGRAMMING When an PCM and the WIN are replaced at the same time, perform the following steps in order: 1. Program the new WIN. 2. Replace all ignition keys and program them to the new WIN. PROGRAMMING THE WIN CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. NOTE: Have a unique vehicle PIN readily available before running the routine CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 3. Select "ECU View." 4. Select "WIN". 5. Select "Miscellaneous Functions." 6. Select "WIN Replaced". 7. Enter the PIN when prompted. 8. Cycle ignition key after the successful routine completion. NOTE: If the PCM and the WIN are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new WIN. PROGRAMMING IGNITION KEYS TO THE WIN Each FOBIK has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the WIN, the module learns the transponder ID code and the transponder acquires the unique Secret Key ID code from the WIN. CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3201 4. Ignition key should be in RUN position. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "Program Ignition Keys or Key FOBs", Start 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned by the WIN. Once a key is learned by a WIN, that key has acquired the Secret Key for that WIN and cannot be transferred to any other WIN or vehicle. PROGRAMMING THE PCM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. 4. Ignition key should be in RUN position. CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "PCM Replaced". 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3202 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL - NGC CONTROLLER NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and the negative battery cable must be disconnected before unplugging the PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the 4 electrical connectors at the PCM. 3. Remove the 3 fasteners (1) holding the PCM to the bracket. Powertrain Control Module - Installation INSTALLATION - NGC CONTROLLER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3203 NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM to bracket with 3 fasteners (1). 2. Install and lock the 4 electrical connectors to the PCM. 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 4. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 3208 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module Fuel Level Sensor: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 3213 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 3214 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 3215 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 3218 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3221 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3222 Fuel Level Sensor: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3225 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3226 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3227 1. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3228 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3229 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3230 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3231 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3232 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3233 Fuel Level Sensor: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3234 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3235 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Information Bus: Electrical Diagrams BUS COMMUNICATIONS - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 Bus Communications 8W-18-01 Bus Communications 8W-18-02 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 Bus Communications 8W-18-03 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 Bus Communications 8W-18-04 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Bus Communications 8W-18-05 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 Bus Communications 8W-18-06 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 Bus Communications 8W-18-07 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 Bus Communications 8W-18-08 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description Information Bus: Description and Operation Communication - Description DESCRIPTION The primary on-board communication network between microprocessor-based electronic control modules in this vehicle is the Controller Area Network (CAN) data bus system. A data bus network minimizes redundant wiring connections; and, at the same time, reduces wire harness complexity, sensor current loads and controller hardware by allowing each sensing device to be connected to only one module (also referred to as a node). Each node reads, then broadcasts its sensor data over the bus for use by all other nodes requiring that data. Each node ignores the messages on the bus that it cannot use. The CAN bus is a two-wire multiplex system. Multiplexing is any system that enables the transmission of multiple messages over a single channel or circuit. The CAN bus is used for communication between most vehicle nodes. However, in addition to the CAN bus network, certain nodes may also be equipped with a Local Interface Network (LIN) data bus. The LIN data bus is a single wire low-speed (9.6 Kbps) serial link bus used to provide direct communication between a LIN master module and certain switch or sensor inputs. There are actually three separate CAN bus systems used in the vehicle. They are designated: the CAN-Interior (also known as CAN Interior High Speed/IHS), the CAN-C and the Diagnostic CAN-C. The CAN-Interior and CAN-C systems provide on-board communication between all nodes in the vehicle. The CAN-C is the faster of the two systems providing near real-time communication (500 Kbps). The CAN-C is used typically for communications between more critical nodes, while the slower (125 Kbps) CAN-Interior system is used for communications between less critical nodes. The added speed of the CAN data bus is many times faster than previous data bus systems. This added speed facilitates the addition of more electronic control modules or nodes and the incorporation of many new electrical and electronic features in the vehicle. The Diagnostic CAN-C bus is also capable of 500 Kbps communication, and is sometimes informally referred to as the CAN-D system to differentiate it from the other high speed CAN-C bus. The Diagnostic CAN-C is used exclusively for the transmission of diagnostic information between the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) and a diagnostic scan tool connected to the industry-standard 16-way Data Link Connector (DLC) located beneath the instrument panel on the driver side of the vehicle. The TIPM is located in the engine compartment near the battery. The central CAN gateway or hub module integral to the TIPM is connected to all three CAN buses. This gateway physically and electrically isolates the CAN buses from each other and coordinates the bi-directional transfer of messages between them. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description > Page 3264 Information Bus: Description and Operation Communication - Operation OPERATION The Controller Area Network (CAN) data bus allows all electronic modules or nodes connected to the bus to share information with each other. Regardless of whether a message originates from a module on the lower speed CAN-Interior (also known as CAN Interior High Speed/IHS) bus or on the higher speed CAN-C or CAN-D bus, the message structure and layout is similar, which allows the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) to process and transfer messages between the CAN buses. The TIPM also stores a Diagnostic Trouble Code (DTC) for certain bus network faults. All modules (also referred to as nodes) transmit and receive messages over one of these buses. Data exchange between nodes is achieved by serial transmission of encoded data messages. Each node can both send and receive serial data simultaneously. Each digital bit of a CAN bus message is carried over the bus as a voltage differential between the two bus circuits which, when strung together, form a message. Each node uses arbitration to sort the message priority if two competing messages are attempting to be broadcast at the same time. The Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is the Local Interface Network (LIN) master module in this vehicle and it gathers information from the compass module, the instrument panel switch bank, the Steering Control Module (SCM), and the Heated Seat Module (HSM) through the LIN data bus. There is also LIN bus communication between the individual Tire Pressure Monitor (TPM) transponders and the Wireless Ignition Node (WIN). Both the EMIC and the WIN either act directly upon the information received through the LIN data bus, relay the information to other nodes in the vehicle using electronic messages placed on the CAN bus, or both. The voltage network used to transmit messages requires biasing and termination. Each module on the CAN bus network provides its own biasing and termination. There are two types of nodes used in the CAN bus network. On the CAN-C or the IHS bus, a dominant node has a 120 ohm termination resistance while a non-dominant (or recessive) node has about a 2500 to 3000 ohm (2.5 to 3.0 kilohm) termination resistance. The dominant nodes on the CAN-C bus are the WIN and the Powertrain Control Module (PCM). The dominant nodes on the IHS bus are the EMIC and the TIPM. The termination resistance of two dominant nodes is combined in parallel to provide a total of about 60 ohms. This resistance value may vary somewhat by application, depending upon the number of non-dominant nodes on the bus. On the CAN-D bus (or Diagnostic CAN-C) all of the 60 ohm termination resistance is present in the Central GateWay (TIPMCGW). NOTE: All measurement of termination resistance is done with the vehicle battery disconnected. The communication protocol being used for the CAN data bus is a non-proprietary, open standard adopted from the Bosch CAN Specification 2.0b. The CAN-C is the faster of the two primary buses in the CAN bus system, providing near real-time communication (500 Kbps). The CAN bus nodes are connected in parallel to the two-wire bus using a twisted pair, where the wires are wrapped around each other to provide shielding from unwanted electromagnetic induction, thus preventing interference with the relatively low voltage signals being carried through them. The twisted pairs have between 33 and 50 twists per meter (yard). While the CAN bus is operating (active), one of the bus wires will carry a higher voltage and is referred to as the CAN High or CAN bus (+) wire, while the other bus wire will carry a lower voltage and is referred to as the CAN Low or CAN bus (-) wire. Refer to the CAN Bus Voltages table. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description > Page 3265 In order to minimize the potential effects of Ignition-OFF Draw (IOD), the CAN-Interior network employs a sleep strategy. However, a network sleep strategy should not be confused with the sleep strategy of the individual nodes on that network, as they may differ. For example: The CAN-C bus network is awake only when the ignition switch is in the ON or START positions; however, the TIPM, which is on the CAN-C bus, may still be awake with the ignition switch in the ACCESSORY or UNLOCK positions. The integrated circuitry of an individual node may be capable of processing certain sensor inputs and outputs without the need to utilize network resources. The CAN-Interior bus network remains active until all nodes on that network are ready for sleep. This is determined by the network using tokens in a manner similar to polling. When the last node that is active on the network is ready for sleep, and it has already received a token indicating that all other nodes on the bus are ready for sleep, it broadcasts a bus sleep acknowledgment message that causes the network to sleep. Once the CAN-Interior bus network is asleep, any node on the bus can awaken it by transmitting a message on the network. The TIPM will keep either the CAN-Interior or the CAN-C bus awake for a timed interval after it receives a diagnostic message for that bus over the Diagnostic CAN-C bus. In the CAN system, available options are configured into the TIPM at the assembly plant, but additional options can be added in the field using the diagnostic scan tool. The configuration settings are stored in non-volatile memory. The TIPM also has two 64-bit registers, which track each of the as-built and currently responding nodes on the CAN-Interior and CAN-C buses. The TIPM stores a Diagnostic Trouble Code (DTC) in one of two caches for any detected active or stored faults in the order in which they occur. One cache stores powertrain (P-Code), chassis (C-Code) and body (B-Code) DTCs, while the second cache is dedicated to storing network (U-Code) DTCs. If there are intermittent or active faults in the CAN network, a diagnostic scan tool connected to the Diagnostic CAN-C bus through the 16-way Data Link Connector (DLC) may only be able to communicate with the TIPM. To aid in CAN network diagnosis, the TIPM will provide CAN-Interior and CAN-C network status information to the scan tool using certain diagnostic signals. In addition, the transceiver in each node on the CAN-C bus will identify a bus off hardware failure, while the transceiver in each node on the CAN-Interior bus will identify a general bus hardware failure. The transceivers for some CAN-Interior nodes will also identify certain failures for both CAN-Interior bus signal wires. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3269 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3270 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3273 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3278 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3279 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 3282 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3286 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3287 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-MANIFOLD ABSOLUTE PRESSURE (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3288 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. MAP SENSOR WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3289 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3290 - Go to 4 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3291 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 3.5L 1. Disconnect and isolate negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Rotate sensor. 4. Lift to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3294 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 3.5L 1. Install sensor. 2. Rotate sensor into position. 3. Attach electrical connector (1) to sensor (2). 4. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3299 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3300 Oxygen Sensor: Locations Sensor - Oxygen 2/1 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3301 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3302 Oxygen Sensor: Locations Sensor - Oxygen 2/2 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3303 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Gas) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 3306 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Gas) (Engine) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 3307 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 3308 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3309 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3310 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3311 Yes - Go to 4 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3312 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove O2S (2) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (5). 6. Remove O2S (3) from catalytic converter (4). DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3315 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove the O2S (5) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (2). 6. Remove O2S (3) from catalytic converter (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3316 Oxygen Sensor: Service and Repair Installation 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (2). 3. Install the O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3317 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (5). 3. Install O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3327 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3328 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3329 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3330 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3331 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3332 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3333 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3334 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3335 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3336 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3337 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: Customer Interest Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 3347 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 3352 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: Customer Interest Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 3357 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 3362 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: Customer Interest Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 3367 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 3373 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 3378 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 3383 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 3388 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3393 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3394 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3395 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3396 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3397 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3398 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3399 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3400 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3401 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3402 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3403 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 3412 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function Engine Control Module: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 3418 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 3423 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 3428 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 3433 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Engine Control Module: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 3438 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3444 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3445 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3446 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3447 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3448 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3449 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3450 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3451 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3452 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3453 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3454 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 3461 Engine Control Module: Locations Powertrain Control Module (NGC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Powertrain Control Module (GPEC) > Page 3462 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way Connector C1 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3465 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3466 Engine Control Module: Diagrams Powertrain Control Module C2 (NGC) (Engine) 38 Way Connector C2 (NGC) - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (ENGINE) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3467 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3468 Engine Control Module: Diagrams Powertrain Control Module C3 (NGC) (Headlamp And Dash) 38 Way Connector C3 (NGC) - (HEADLAMP AND DASH) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (HEADLAMP AND DASH) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3469 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3470 Engine Control Module: Diagrams Powertrain Control Module C4 (NGC) (Transmission) 38 Way Connector C4 (NGC) - (TRANSMISSION) 38 WAY MODULE-POWERTRAIN CONTROL (NGC) - (TRANSMISSION) 38 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (NGC) (Headlamp And Dash) 38 Way > Page 3471 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - ASD/Main Relay - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback (if equipped) - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Inlet Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral (from trans range sensor) - Power Steering Pressure Switch - Proportional Purge Sense - CAN C Bus - Speed Control - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Data Link Connector (CAN C Bus) - Double Start Override - EGR Solenoid (if equipped) - Fuel Injectors - Generator Field - High Speed Fan Relay - Ignition Coils - Natural Vacuum Leak Detection - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - 5 Volt Output Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation and EGR if equipped. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3474 rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Manifold Absolute Pressure - Engine Speed (crankshaft position sensor) - Battery Voltage - Inlet Air Temperature Sensor - Engine Coolant Temperature - Exhaust Gas Oxygen Content (heated oxygen sensors) - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed (from Transmission Control Module) The PCM adjusts ignition timing based on the following inputs. - Inlet Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral (from trans range sensor) - Transaxle Gear Engagement - Throttle Position The camshaft and crankshaft signals are sent to the Powertrain Control Module (PCM). If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the fuel pump. When deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. The PCM contains a voltage converter that changes battery voltage to a regulated 5.0 volts. The 5.0 volts power the camshaft position sensor, and crankshaft position sensor. The PCM also provides a regulated 5.0 volts supply for the, manifold absolute pressure sensor, throttle position sensor and EGR (if equipped). The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the scan tool to change the mileage in the PCM. Refer to the appropriate Powertrain Diagnostic Manual and the scan tool. If equipped with SKREEM, must use SKREEM function to program VIN number in new PCM. TRANSMISSION CONTROL CVI CALCULATION An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3475 Gear ratios can be determined by using the scan tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES The PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3476 Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Replacement PCM REPLACEMENT DESCRIPTION Use the scan tool to reprogram the new pcm with the vehicle's original identification number (vin) and the vehicle's original mileage. If this step is not done a Diagnostic Trouble Code (DTC) may be set. PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side of relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded via the mounting screws AND bracket to the chassis, separately from the ground pins. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3477 Engine Control Module: Description and Operation Powertrain Control Module - Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pullup resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3478 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3479 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. CHECKING THE PCM FUSED B+ CIRCUITS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3480 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Using a 12 volt test light connected to ground, check the PCM power supply circuits. 2. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go to 4. No - Repair the PCM power supply circuit(s) for an open circuit or high resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 4. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM (F202) and (F1) Fused Ignition circuits. 3. Wiggle test each circuit during the test to check for an intermittent open or short in the circuit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3481 NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Go to 5. No - Repair the open or short in the Fused Ignition Switch circuits. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. CHECKING THE PCM FUSED IGNITION SWITCH CIRCUITS 1. Turn the ignition on. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition Switch circuits. 3. Check each circuit with the ignition off, ignition on, engine not running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the PCM Fused Ignition Switch circuit(s) for as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. PCM/TCM Programming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3484 > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using wiTECH(TM) Diagnostic Application. Go To REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See SECTION 3 AUTHORIZED MODIFCATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3485 SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Aisin TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quick learn Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3486 If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3487 - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3488 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Quick learn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quick learn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFCATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3489 TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids', under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Module/Programming Order Replacement Guide MODULE/PROGRAMMING ORDER REPLACEMENT GUIDE Module Programming Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3490 MODULE PROGRAMMING The Wireless Ignition Node (WIN) controls the Vehicle Theft Security System (VTSS), Remote Keyless Entry (RKE). When a Powertrain Control Module (PCM) is in need of replacement, perform the following steps in order: NOTE: The PCM and the WIN should never be replaced at the same time. They should be replaced independently of each other. 1. If applicable, first replace the PCM with the original WIN still connected to the vehicle. 2. Using a scan tool program the new PCM. (This will ensure the transfer of the Secret Key data from the original WIN into the new PCM). 3. Replace the WIN, using the scan tool program the new WIN module. This will transfer the Secret Key data from the PCM into the new WIN. 4. With the scan tool reprogram the key FOBIK to the new WIN. 5. Ensure all the customer's keys have been programmed to the new module. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SECRET KEY TO THE WIN The secret key is an ID code that is unique to each WIN. This code is programmed and stored in the WIN, the PCM, and each ignition key transponder chip. When the PCM or WIN is replaced, it is necessary to program the Secret Key Code into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, WIN REPLACED, or TIPM REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE menu item as appropriate. NOTE: Programming the PCM or WIN is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour and then enter the correct PIN. Be certain that all accessories are turned OFF. Also, monitor the battery state and connect a battery charger if necessary. PCM/WIN PROGRAMMING When an PCM and the WIN are replaced at the same time, perform the following steps in order: 1. Program the new WIN. 2. Replace all ignition keys and program them to the new WIN. PROGRAMMING THE WIN CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. NOTE: Have a unique vehicle PIN readily available before running the routine CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 3. Select "ECU View." 4. Select "WIN". 5. Select "Miscellaneous Functions." 6. Select "WIN Replaced". 7. Enter the PIN when prompted. 8. Cycle ignition key after the successful routine completion. NOTE: If the PCM and the WIN are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new WIN. PROGRAMMING IGNITION KEYS TO THE WIN Each FOBIK has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the WIN, the module learns the transponder ID code and the transponder acquires the unique Secret Key ID code from the WIN. CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3491 4. Ignition key should be in RUN position. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "Program Ignition Keys or Key FOBs", Start 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. NOTE: If the original keys do not successfully program to the new WIN after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned by the WIN. Once a key is learned by a WIN, that key has acquired the Secret Key for that WIN and cannot be transferred to any other WIN or vehicle. PROGRAMMING THE PCM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. 3. Have a unique vehicle PIN readily available before running the routine. 4. Ignition key should be in RUN position. CAUTION: If the PCM and WIN are replaced at the same time, the PCM MUST be programmed before the WIN. 5. Select "ECU View". 6. Select "WIN Wireless Control". 7. Select "Miscellaneous Functions." 8. Select "PCM Replaced". 9. Enter the PIN when prompted. 10. Verify the correct information. 11. Cycle ignition key after the successful routine completion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3492 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL - NGC CONTROLLER NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and the negative battery cable must be disconnected before unplugging the PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the 4 electrical connectors at the PCM. 3. Remove the 3 fasteners (1) holding the PCM to the bracket. Powertrain Control Module - Installation INSTALLATION - NGC CONTROLLER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3493 NOTE: USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM to bracket with 3 fasteners (1). 2. Install and lock the 4 electrical connectors to the PCM. 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 4. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3498 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3499 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 3502 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3507 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 3512 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 3517 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3518 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3519 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3522 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way Connector (3.5L EARLY BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L EARLY BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (3.5L Early Build) (Engine) 2 Way > Page 3528 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (3.5L Normal Build) (Engine) 2 Way Connector (3.5L NORMAL BUILD) - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (3.5L NORMAL BUILD) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3529 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor value on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3530 NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 5. (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3531 No - Repair the (K2) ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3535 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3536 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3539 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 3544 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 3549 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module Fuel Level Sensor: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 3554 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 3555 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Pump Module > Page 3556 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 3559 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3562 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3563 Fuel Level Sensor: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3566 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3567 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3568 1. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3569 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3570 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3571 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3572 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3573 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3574 Fuel Level Sensor: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3575 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3576 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair/Fuel Pump Module Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3580 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3581 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (HEADLAMP AND DASH) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable. NOTE: Clean dirt from sensor area prior to removal from air box. 2. Disconnect the inlet air temperature sensor electrical connector (1). 3. Remove the inlet air temperature sensor (2) from the air box (3) by turning the sensor 1/4 turn in the counter - clockwise direction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3584 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the inlet air temperature sensor (2) to the air box (3) by turning the sensor 1/4 turn in the clockwise direction. 2. Connect the inlet air temperature sensor electrical connector (1). 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3588 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3589 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal > Page 3592 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3596 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3597 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-MANIFOLD ABSOLUTE PRESSURE (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3598 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. MAP SENSOR WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3599 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3600 - Go to 4 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3601 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 3.5L 1. Disconnect and isolate negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Rotate sensor. 4. Lift to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3604 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 3.5L 1. Install sensor. 2. Rotate sensor into position. 3. Attach electrical connector (1) to sensor (2). 4. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3609 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3610 Oxygen Sensor: Locations Sensor - Oxygen 2/1 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3611 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3612 Oxygen Sensor: Locations Sensor - Oxygen 2/2 (2.7L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (Gas) > Page 3613 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Gas) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 3616 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Gas) (Engine) 4 Way Connector (GAS) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 3617 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Gas) 4 Way > Page 3618 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (2.7L/3.5L) (Engine) 4 Way Connector (2.7L/3.5L) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (2.7L/3.5L) - (ENGINE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3619 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3620 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3621 Yes - Go to 4 - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3622 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM Verification Test. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove O2S (2) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (5). 6. Remove O2S (3) from catalytic converter (4). DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3625 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor (O2S). Damage to the oxygen sensor may occur. NOTE: Use an O2S removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness from engine wiring harness (1). 4. Remove the O2S (5) from catalytic converter (4). 5. Disconnect O2S pigtail harness from engine wiring harness (2). 6. Remove O2S (3) from catalytic converter (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3626 Oxygen Sensor: Service and Repair Installation 2.7, 3.5L DOWNSTREAM OXYGEN SENSOR (2/2) AND UPSTREAM OXYGEN SENSOR (2/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (2). 3. Install the O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. DOWNSTREAM OXYGEN SENSOR (1/2) AND UPSTREAM OXYGEN SENSOR (1/1) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3627 WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2S (3) to catalytic converter (4). 2. Connect O2S pigtail harness to engine wiring harness (5). 3. Install O2S (2) to catalytic converter (4). Tighten to 41 Nm (30 ft. lbs.). 4. Connect O2S pigtail harness to engine wiring harness (1). 5. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3631 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3634 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3635 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3636 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3637 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3638 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3642 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3645 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3646 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3647 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3648 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3649 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Description Air Injection Check Valve: Description and Operation Description DESCRIPTION The air injection check valve (1) is a one-valve check valve that allows air to flow in one direction only. The valve is located at exhaust side of the engine at the top of the exhaust manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Description > Page 3656 Air Injection Check Valve: Description and Operation Operation OPERATION The air injection check valve (1) allows air pumped from the air injection pump to enter the exhaust manifold during cold engine starts only. Air pressure from the air injection pump causes the spring inside the air injection check valve to open allowing air to flow into the exhaust system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Removal Air Injection Check Valve: Service and Repair Removal REMOVAL WARNING: THE EXHAUST MANIFOLD, AIR INJECTION PIPES, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING AIR INJECTION CHECK VALVE. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. 1. Remove engine cover. 2. Remove air outlet tube (3) by pushing the ends (2) together, while pulling the air pump outlet tube (3) away from air injection check valve (1). 3. Remove air injection check valve mounting bolts (4). 4. Remove air injection check valve (1) and gasket (5) from pipe. Clean old gasket material from air injection pipe. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Service and Repair > Removal > Page 3659 Air Injection Check Valve: Service and Repair Installation INSTALLATION NOTE: Make sure the old gasket material is completely removed from air injection pipe. 1. Install new gasket (5) and air injection check valve (1) to pipe. 2. Install air injection check valve mounting bolts (4). NOTE: The quick connect fitting on the air outlet tube is slotted to fit the air injection check valve fitting. Line the slot up when making the connection. 3. Install air pump outlet tube (3) to air injection check valve (1) connection. A click noise will indicate a good connection. 4. Install engine cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 3664 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Description and Operation Air Injection Hose/Tube: Description and Operation DESCRIPTION The air pump inlet tube is located on the left side of the engine compartment. The tube attaches to the air injection pump using a quick connect style fitting. The other end of the tube connects to the mass air flow sensor using a constant tension clamp. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Service and Repair > Removal Air Injection Hose/Tube: Service and Repair Removal REMOVAL 1. Cut the tie straps (3) being careful not to damage the air inlet tube (4). 2. Remove the constant tension clamp (2) and remove the mass air flow (MAF) sensor (1) from the air inlet tube (4). Position MAF sensor (1) and wiring aside. 3. Remove air inlet tube (3) by pushing the ends (1) together, while pulling the air inlet tube (3) away from air pump housing connection (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Service and Repair > Removal > Page 3670 Air Injection Hose/Tube: Service and Repair Installation INSTALLATION NOTE: The quick connect fitting on the air inlet tube is slotted to fit the air pump housing fitting. Line the slot up when making the connection. 1. Install air inlet tube (3) to air pump housing connection (2). A click noise will indicate a good connection. 2. Install mass air flow (MAF) sensor (1) and constant tension clamp (2) to air inlet tube (4). 3. Position MAF sensor wiring to air inlet tube (4). Install new tie straps (3) securing the MAF sensor wiring to air inlet tube (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation > Description Air Injection Pump: Description and Operation Description DESCRIPTION The air injection pump is located on the left side of the engine compartment. The pump is operated by an internal electrical motor and is mounted to a bracket by rubber isolators. An inlet and outlet air hoses are attached to the air pump. A heat shield is attached at the air pump mounting bracket to ensure that the air pump is not damaged by heat coming off the exhaust system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation > Description > Page 3675 Air Injection Pump: Description and Operation Operation OPERATION The electric air pump only functions during cold starts. The PCM will not command the electric air pump to run if the engine coolant temperature is 10° Celsius (18° Fahrenheit) above ambient temperature or if the engine coolant temperature is above 37° Celsius (98.6° Fahrenheit). The air pump will not run more than 20 seconds during this cold start condition. The air inlet tube to the electric air pump is equipped with a mass air flow (MAF) sensor. This MAF sensor monitors air flow to the exhaust system and is used to diagnose the system by making sure the correct amount of air, not too much or too little, reaches the exhaust system. Each component of the secondary air system is diagnosed assuming the other part is functioning correctly. The diagnostic tool can command the air pump ON with the key ON and engine OFF (KOEO). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Service and Repair > Removal Air Injection Pump: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery. 2. Remove engine cover. 3. Remove air inlet tube (3) by pushing the ends (1) together while pulling the air inlet tube (3) away from air pump housing connection (2). 4. Remove air outlet tube by pushing the coupling ends together while pulling the air outlet tube away from the air pump. 5. Remove bolt (1) from heat shield (2) and air pump bracket (3). 6. Remove heat shield bolt (1) and heat shield (3) from air pump bracket (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Service and Repair > Removal > Page 3678 7. Disconnect electrical harness connector (1) from the air pump electrical connector (2). 8. Remove air pump and bracket assembly from vehicle. 9. Remove air pump mounting nuts (5) from bracket (4). 10. Remove air pump (3) from bracket (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Service and Repair > Removal > Page 3679 Air Injection Pump: Service and Repair Installation INSTALLATION 1. Install air pump (3) to bracket (4). 2. Install air pump mounting nuts (5) to bracket (4). Tighten the nuts to 8 Nm (71 in. lbs.). 3. Position air pump and bracket assembly in vehicle. 4. Connect electrical harness connector (1) to the air pump electrical connector (2). 5. Install heat shield (3) and bolt (1) to air pump bracket (2). Tighten the bolt to 8 Nm (71 in. lbs.). 6. Install relay, heat shield (2) and bolt (1) to air pump bracket (3). Tighten the bolt to 8 Nm (71 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Service and Repair > Removal > Page 3680 NOTE: The quick connect fitting on the air inlet tube is slotted to fit the air pump housing fitting. Line the slot up when making the connection. 7. Install air inlet tube (3) to air pump housing connection (2). A click noise will indicate a good connection. 8. Install air outlet tube to air pump housing. A click noise will indicate a good connection. 9. Connect the negative battery cable, tighten the nut to 5 Nm (45 in. lbs.). 10. Install engine cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 3686 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3691 Canister Purge Solenoid: Diagrams Connector (GAS) - (HEADLAMP AND DASH) 2 WAY SOLENOID-EVAP PURGE (GAS) - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3692 Canister Purge Solenoid: Description and Operation OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 Hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal Canister Purge Solenoid: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable at battery. 2. If equipped with 3.5L engine, remove the PCM See: Computers and Control Systems/Engine Control Module/Service and Repair/Removal and Replacement/Powertrain Control Module - Removal. 3. Disconnect electrical connector (2) from evaporator purge solenoid (1). 4. Remove purge hose and quick connect fuel tank hose (3) from evaporator purge solenoid (1) See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 5. Release tab to remove evaporator purge solenoid (1) from bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal > Page 3695 Canister Purge Solenoid: Service and Repair Installation INSTALLATION 1. Install evaporator purge solenoid (1) to bracket. Make sure the tab secures the solenoid to the bracket. 2. Install quick connect fuel tank hose and purge hose (3) to evaporator purge solenoid (1) See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 3. Connect electrical connector (2) to evaporator purge solenoid (1). 4. If equipped with 3.5L engine, install the PCM See: Computers and Control Systems/Engine Control Module/Service and Repair/Removal and Replacement/Powertrain Control Module - Installation. 5. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3704 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3705 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3711 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3712 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation Evaporative Emission Control Canister: Description and Operation OPERATION All gasoline fueled vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The Powertrain Control Module (PCM) purges the canister through the proportional purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal Evaporative Emission Control Canister: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable. 2. Remove the spare tire, refer to the owners manual. 3. Raise and support vehicle. 4. Remove the 4 nuts (1) and the spare tire well (2). 5. Remove 2 nuts from EVAP canister mounting brackets and reposition EVAP canister assembly. 6. Disconnect purge line (4) from EVAP canister (1) See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 7. Remove fresh air hose (2) and electrical connector (3) from the ESIM. 8. Remove EVAP canister assembly from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3718 9. A lock tab (see arrow) is used on the back of the switch. Push lock tab towards switch while rotating switch counterclockwise 1/4 turn for removal. 10. Remove ESIM (1) from the EVAP canister (3). 11. Remove mounting brackets from EVAP canister. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3719 Evaporative Emission Control Canister: Service and Repair Installation INSTALLATION The picture displays a typical EVAP Canister and a typical ESIM switch. After installing any ESIM switch, the electrical connector on the switch must be in the 3 O'clock position. This step must be done for proper ESIM switch operation. 1. The fresh air hose that attaches to the ESIM must have a clear opening to the atmosphere. Check the fresh air hose, including the fresh air filter, for obstructions or restrictions at the ESIM. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill. 2. Be sure O-ring (2) and EVAP canister opening are clean. 3. Install ESIM (1) to the EVAP canister (3). 4. Instal mounting brackets to EVAP canister assembly. 5. Install EVAP canister assembly to vehicle. 6. Install purge line (4) to EVAP canister (1) See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. 7. Install fresh air hose (2) and electrical connector (3) to the ESIM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3720 8. Install the spare tire well (2) with 4 nuts (1). 9. Lower vehicle. 10. Install the spare tire, refer to the owners manual. 11. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3729 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3730 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3736 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3737 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3741 Leak Detector: Diagrams Connector (GAS) - (BODY) 2 WAY SWITCH-EVAP SYSTEM MONITOR (GAS) - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3742 Leak Detector: Description and Operation OPERATION SYSTEM The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM requires an adaptor to maintain a vertical position. When the ESIM is installed vertically, the electrical connector is in the 3 o'clock position. EXPLODED VIEW Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3743 The ESIM assembly consists of a housing, a small weight and a large weight that serve as check valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large weight check valve seals for pressure. The small weight check valve seals for vacuum. The weighted check valves are contained within the ESIM housing. CUT AWAY OF MODULE The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system, performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM has been simplified because the solenoid used on the NVLD is not used on the ESIM. The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm, a switch and a cover. The larger check valve seals for pressure and the smaller one seals for vacuum. During refueling, pressure is built up in the evaporative system. When pressure reaches approximately.5 inches of water, the large check valve unseats and pressure vents to the fresh air filter. Conversely, when the system cools and the resulting vacuum lifts the small check valve from its seat and allows fresh air to enter the system and relieve the vacuum condition. When a calibrated amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing on the spring and closing the contacts. The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for small leaks and an engine running, intrusive test for medium/large leaks. The ESIM weights seal the EVAP system during engine off conditions. If the EVAP system is sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1" H20, the vacuum switch closes. The switch closure sends a signal to the powertrain control module (PCM). In order to pass the non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and within a specified amount of key-off events. If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive engine running test will be run during the next key-on cycle. This intrusive test will run on the next cold engine running condition. Conditions for running the intrusive test are: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3744 - After the vehicle is started, the engine coolant temperature must be within 10° C (50°F) of ambient to indicate a cold start. - The fuel level must be between 12% and 88%. - The engine must be in closed loop. - Manifold vacuum must be greater than a minimum specified value. - Ambient temperature must be between 4° C and 37° C (39° F and 98° F) and the elevation level must be below 8500 feet. The test is accomplished by the PCM activating the purge solenoid to create a vacuum in the evaporative system. The PCM then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the switch does not close, then a general evaporative failure is recorded. Even when all of the thresholds are met, a small leak won't be recorded until after the medium/large leak monitor has been run. If the medium/large leak test runs and the ESIM switch doesn't close, a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds, increasing the amount of vacuum in the system. IF the ESIM switch closes after the extended purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative system fault is generated. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Stage one of the purge monitor is non-intrusive. The PCM monitors the purge vapor ratio. If the ratio is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs only if stage one fails. During the stage two test, the PCM commands the purge solenoid to flow at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a calibrated specification and if it is less than specified, a one-trip failure is recorded. The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power down test that runs at key-off; when the PCM sees 0 rpm's, the purge solenoid is energized for a maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch opens or was open before the test began, the monitor passes. If the switch doesn't open, the monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stuck closed monitor to run. The PCM also uses the ESIM to detect a loose or missing gas cap. The PCM looks for a change in the fuel level (25% minimum). If a medium/large leak is then detected, a loose gas cap light illuminates and a pending one-trip fault code is set. This is a three-trip fault before the code matures. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal Leak Detector: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable. 2. Remove the spare tire, refer to the owners manual. 3. Raise and support vehicle. 4. Remove the 4 nuts (1) and the spare tire well (2). 5. Remove fresh air hose (2) and electrical connector (3) from the ESIM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal > Page 3747 6. A lock tab (see arrow) is used on the back of the switch. Push lock tab towards switch while rotating switch counterclockwise 1/4 turn for removal. 7. Remove ESIM (1) from the EVAP canister (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal > Page 3748 Leak Detector: Service and Repair Installation INSTALLATION The picture displays a typical EVAP Canister and a typical ESIM switch. After installing any ESIM switch, the electrical connector on the switch must be in the 3 O'clock position. This step must be done for proper ESIM switch operation. 1. The fresh air hose that attaches to the ESIM must have a clear opening to the atmosphere. Check the fresh air hose, including the fresh air filter, for obstructions or restrictions at the ESIM. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill. 2. Be sure O-ring (2) and EVAP canister opening are clean. 3. Install ESIM (1) to the EVAP canister (3). 4. Install fresh air hose (2) and electrical connector (3) to the ESIM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal > Page 3749 5. Install the spare tire well (2) with 4 nuts (1). 6. Lower vehicle. 7. Install the spare tire, refer to the owners manual. 8. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation EGR Cooler: Description and Operation DESCRIPTION The EGR cooler (7) cools recirculated exhaust gasses to reduce combustion temperature and a greater mass of exhaust gases can thus be circulated. There is less nitrogen oxides as a result. The EGR cooler (7) allows the engine and catalytic converter to reach their operating temperature quickly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > EGR Cooler - Removal EGR Cooler: Service and Repair EGR Cooler - Removal REMOVAL 1. Remove engine cover See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine - Removal. 2. Drain cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 3. Remove EGR cooler coolant hoses (8). 4. Remove EGR cooler to exhaust manifold tube (11). 5. Remove EGR cooler to EGR valve tube (1). 6. Remove EGR cooler mounting nuts (6). 7. Remove EGR cooler (7). 8. Remove the bypass valve mounting screws (3). 9. Separate the bypass valve assembly from the EGR cooler body (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > EGR Cooler - Removal > Page 3756 EGR Cooler: Service and Repair EGR Cooler - Installation INSTALLATION 1. Using a new gasket, position the bypass valve assembly to the EGR cooler body (5). Tighten screws to 10 Nm (88 in. lbs.). 2. Position EGR cooler (7) and install mounting screws. Tighten to 10 Nm (88 in. lbs.). 3. Install EGR cooler to exhaust manifold tube (11). Tighten bolts to 20 Nm (14 ft. lbs.) and nuts to 20 Nm (14 ft. lbs.). 4. Install EGR cooler to EGR valve tube (1). Tighten bolts to 20 Nm (14 ft. lbs.). 5. Install coolant hoses. 6. Install vacuum line. 7. Fill cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 8. Install engine cover See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Tube - Removal EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) Tube - Removal 3.5L WARNING: The normal operating temperature of the exhaust gas recirculate (EGR) valve and tube is very high. Therefore, never work around or attempt to service any engine component until it is completely cooled. 1. Remove two upper tube mounting bolts. 2. When removing EGR tube assembly be careful not to drop the silicone rubber seals into the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum. 3. Remove two lower tube mounting bolts. 4. Remove tube assembly from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Tube - Removal > Page 3761 EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) Tube - Installation 3.5L CAUTION: Do Not use metal scrapers when cleaning the mounting surface of the EGR valve. Damage from scratching the surface may cause an improper seal. CAUTION: Do not allow debris to enter the EGR valve when cleaning the mounting surface. Debris can lodge between the pintle and the seat causing valve leakage that results in rough idle and depressed manifold vacuum. 1. Clean and inspect gasket sealing surfaces. NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold. 2. Install new silicone rubber seal (1) on the intake manifold end of the EGR tube. Position seal 17 mm (0.67 in.) from the tube flange. 3. Lubricate the EGR mounting tube hole in the intake manifold with Mopar(R) Rubber Bushing Installation Lube. Do not lubricate the EGR tube or seal. 4. Install the EGR tube (3) into the intake manifold (2) being careful not to damage the silicone rubber seals, and verify that the seals are correctly positioned in the intake manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Tube - Removal > Page 3762 5. Install new gasket between the EGR valve and tube and install bolts (1). Tighten bolts to 15 Nm (11 ft. lbs.). NOTE: The EGR tube flange (1) does not need to be flush with the intake manifold (2) to be sealed. The EGR tube flange can be up to 2 mm (0.08 in.) from intake manifold and still be sealed. This design allows the EGR tube position to vary with the tolerance stack up and remain properly sealed. CAUTION: DO NOT use air tools to install bolts to intake manifold. Install bolts using hand tools only. Torque all fasteners to specification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Tube - Removal > Page 3763 The use of air tools can cause the threads of the intake manifold to become stripped. 6. Install the EGR tube flange mounting bolts to intake manifold. Tighten bolts to 12 Nm (106 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3767 EGR Valve: Diagrams Connector (2.7L/3.5L) - (ENGINE) 6 WAY ASSEMBLY-EGR VALVE (2.7L/3.5L) - (ENGINE) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Exhaust Gas Recirculation (EGR) Valve - Description EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve - Description DESCRIPTION The EGR valve consists of three major components. First there is the pintle, valve seat, and housing which contains and regulates the gas flow. Second there is the armature, return spring, and solenoid coil to provide the operating force to regulate the flow by changing the pintle position. The solenoid coil assembly is in parallel with a diode and connects to the two connectors in the connector assembly. The third major component which senses pintle position and is connected to the three connectors in the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Exhaust Gas Recirculation (EGR) Valve - Description > Page 3770 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve - Operation OPERATION The exhaust gas recirculation flow is determined by the engine controller. For a given set of conditions, the engine controller knows the ideal exhaust gas recirculation flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The engine controller adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) Valve - Removal 3.5L WARNING: The normal operating temperature of the exhaust gas recirculate (EGR) valve and tube is very high. Therefore, never work around or attempt to service any engine component until it is completely cooled. NOTE: It is very important to disconnect the battery due to the addresses (cells) within the engine controller that store learned values related to powertrain operation. A malfunctioning EGR system can cause bad values to be stored in these cells that can cause an erroneous fault to occur after the system is repaired. Disconnecting the battery for at least two minutes will remove all power from the controller and reset these cells to normal default values. 1. Disconnect and isolate negative battery cable at battery. 2. Remove EGR tube bolts (3) at exhaust gas recirculate (EGR) valve (2). 3. Remove EGR tube (4) from EGR valve (2). 4. Remove and discard gasket (5) located between EGR valve (2) and EGR tube (4). 5. Disconnect electrical connector at EGR valve (2). 6. Remove EGR valve mounting bolts (6). 7. Remove EGR valve (2) from cylinder head (1). 8. Remove and discard gasket located between EGR valve (2) and cylinder head (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 3773 EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) Valve - Installation 3.5L 1. Install new exhaust gas recirculate (EGR) valve gasket to EGR valve. 2. Install EGR valve (2), gasket and bolts (6) to cylinder head (1). Tighten to 31 Nm (23 ft. lbs.). 3. Install new gasket (5), EGR tube (4) and bolts (3) to EGR valve (2). Tighten to 12 Nm (106 in. lbs.). 4. Tighten the EGR tube to intake manifold bolts to 5 Nm (45 in. lbs.). 5. Connect electrical connector to EGR valve (2). 6. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations The Positive Crankcase Ventilation (PCV) valve is located on the end of the rear valve cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Positive Crankcase Ventilation (PCV) Valve - Description Positive Crankcase Ventilation Valve: Description and Operation Positive Crankcase Ventilation (PCV) Valve - Description DESCRIPTION The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Positive Crankcase Ventilation (PCV) Valve - Description > Page 3780 Positive Crankcase Ventilation Valve: Description and Operation Positive Crankcase Ventilation (PCV) Valve - Operation OPERATION When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 3781 Positive Crankcase Ventilation Valve: Testing and Inspection PCV SYSTEM WARNING: apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. 1. With engine idling, remove the hose from the PCV valve. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. A strong vacuum should also be felt when a finger is placed over the valve inlet. 2. Install hose on PCV valve. Remove the make-up air hose from the air plenum at the rear of the engine. Hold a piece of stiff paper (parts tag) loosely over the end of the make-up air hose. 3. After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. If the engine does not draw the paper against the grommet after installing a new valve, replace the PCV valve hose. 4. Turn the engine off. Remove the PCV valve from intake manifold. The valve should rattle when shaken. 5. Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation (PCV) Valve - Removal Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - Removal 3.5L The Positive Crankcase Ventilation (PCV) valve is located on the end of the rear valve cover. 1. Remove positive crankcase ventilation (PCV) hose (2) from PCV valve (3). 2. Unscrew PCV valve (3) from valve cover (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation (PCV) Valve - Removal > Page 3784 Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - Installation 3.5L 1. Install positive crankcase ventilation (PCV) valve (3) to valve cover (1) and tighten to 4 Nm (35 in. lbs.). 2. Install positive crankcase ventilation (PCV) hose (2) to PCV valve (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal Air Injection Flow Sensor: Service and Repair Removal REMOVAL 1. Disconnect air flow sensor electrical connector (4). 2. Remove constant tension clamps (1), (2) securing the air flow sensor (3). 3. Remove air flow sensor (3) from hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Air Injection Flow Sensor > Component Information > Service and Repair > Removal > Page 3790 Air Injection Flow Sensor: Service and Repair Installation INSTALLATION 1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses. 2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses. 3. Connect air flow sensor electrical connector (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation Exhaust Temperature Sensor: Service and Repair Operation EXHAUST TEMPERATURE SENSOR 1. Remove engine cover. 2. Disconnect and isolate negative battery cable. 3. Disconnect upstream DPF temperature sensor electrical connector (1). 4. Remove upstream DPF temperature sensor (2). 5. Disconnect downstream DPF temperature sensor electrical connector (4). 6. Remove downstream DPF temperature sensor (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Operation > Page 3795 Exhaust Temperature Sensor: Service and Repair Installation EXHAUST TEMPERATURE SENSOR 1. Position DPF downstream temperature sensor (3) into DPF. Tighten to 25 Nm (18 ft. lbs.). 2. Connect downstream temperature sensor electrical connector (4). 3. Position DPF upstream temperature sensor (2) into DPF. Tighten to 25 Nm (18 ft. lbs.). 4. Connect upstream temperature sensor electrical connector (1). 5. Install engine cover. 6. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Fuel Flow Leakdown Less than 10 psi in 5 minutes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. FUEL PUMP OPERATION 1. Ignition on, engine not running. 2. With a scan tool, actuate the Fuel System test. NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly with no excessive noise. If the pump has excessive noise such as grinding, the pump should be replaced. CAUTION: Stop All Actuations. Does the Fuel Pump sound to be operate normally? Yes - Go to 2 No - Go to 7 2. FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge. 3. Ignition on, engine not running. 4. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Choose a conclusion that best matches your fuel pressure reading. Below Specification - Go to 3 Within Specification - Test Complete. Above Specification - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3802 Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special tool #6539 (5/16") or #6631(3/8") fuel line adapter and the fuel pressure gauge between the fuel supply line and the fuel pump module. 4. Ignition on, engine not running. 5. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Is the fuel pressure within specification now? Yes - Repair/replace fuel supply line as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. CHECKING FUEL TANK SIPHON HOSE AND FUEL LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the Fuel Pump Module and the Fuel Tank Module. 3. Inspect the following fuel components: Fuel line and siphon hose between the Fuel Pump Module and the Fuel Tank Module. Look for disconnected and/or damaged lines or hoses. - Fuel Pressure Regulator not properly seated in the module. Were the above items in good working condition? Yes - Go to 6 No - Repair or replace as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. CHECKING THE FUEL PUMP INLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3803 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Inlet and the bottom of the fuel tank for debris that could cause the fuel pump inlet to be plugged. Is the Fuel Pump Inlet plugged? Yes - Repair/Replace as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP MOTOR GROUND CIRCUIT 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light to battery voltage, probe the Fuel Pump Motor Ground circuit in the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Does the test light illuminate brightly. Yes - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Motor Ground circuit. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3804 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3805 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3806 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3807 Fuel Pressure: Testing and Inspection Fuel Delivery System Output - Flow Test FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure. - Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. - Use extreme caution when connecting and disconnecting fuel lines. Considerable fuel leakage may occur when servicing the fuel system. Wear protective eyewear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair or replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester 8978A. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3808 Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly 8978A-1 Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: - Open the Fuel System Isolation Valve (1). - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3809 - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 1. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. 2. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa ± 34 kPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 kPa ± 34 kPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Ignition on, engine not running. 2. With the scan tool, actuate the fuel pump. 3. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. 4. Turn the ignition off. 5. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. Does the amount of fuel in the reservoir meet or exceed the specification? Yes - Test complete. No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal Accelerator Pedal: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable at battery. 2. Disconnect the electrical connector from accelerator pedal. 3. Remove mounting nuts and remove accelerator pedal from the mounting studs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal > Page 3817 Accelerator Pedal: Service and Repair Installation INSTALLATION CAUTION: The accelerator pedal and mounting nuts need to be torque in a mandatory torque sequence or damage could result to the pedal assembly. 1. Install the accelerator pedal and mounting nuts to the mounting studs. Tighten the nuts in a mandatory torque sequence to 16 Nm (12 ft. lbs.). 2. Connect the electrical connector from accelerator pedal. 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 4. Use a scan tool and perform the APPS RELEARN function. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3821 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Disengage the air filter housing clips (1). 2. Slide the air filter housing cover (2) forward slightly to disengage tabs from the bottom of the air filter housing. 3. Remove air cleaner element from air cleaner housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 3827 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install air filter element into the bottom half of the air filter housing. 2. Slide the air filter housing cover (2) rearward to engage the tabs into the bottom half of the air filter housing. 3. Reengage the air filter housing clips (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation Fuel: Description and Operation FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded gasoline having an octane rating of 87. The use of premium gasoline is not recommended. The use of premium gasoline will provide no benefit over high quality regular gasoline, and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. Chrysler recommends the use of gasolines that meet the WWFC specifications if they are available. REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as "reformulated" gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. Chrysler strongly supports the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components. GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components. MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. Chrysler recommends that gasoline free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline. SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle's catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. Chrysler recommends that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board diagnostics system section. MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions. FUEL SYSTEM CAUTIONS CAUTION: Follow these guidelines to maintain your vehicle's performance: - The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation > Page 3831 and could result in loss of warranty coverage. - An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. - When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. - The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of Chrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description Fuel Filler Cap: Description and Operation Description DESCRIPTION The plastic fuel fill cap is a threaded/quarter turn onto the end of the fuel filler tube. Its purpose is to retain vapors and fuel in the fuel tank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description > Page 3836 Fuel Filler Cap: Description and Operation Operation OPERATION The loss of any fuel vapor out of fuel filler tube is prevented by the use of pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If the cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove fuel fill cap. 2. Remove fuel pump fuse from Totally Integrated Power Module (TIPM). For location of fuse, refer to label on underside of TIPM cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. 6. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 7. Disconnect quick-connect fitting at fuel rail See: Fuel Line Coupler/Service and Repair. 8. When the repair is complete, reconnect fuel fittings and return fuel pump fuse to TIPM. 9. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump fuse removal. A diagnostic scan tool must be used to erase a DTC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3847 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3848 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3849 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3850 Fuel Injector: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3851 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3852 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3853 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3854 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (2.7/3.5L) > Page 3855 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way Fuel Injector: Diagrams Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 1 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3858 Fuel Injector: Diagrams Fuel Injector 2 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 2 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3859 Fuel Injector: Diagrams Fuel Injector 3 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 3 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3860 Fuel Injector: Diagrams Fuel Injector 4 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 4 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3861 Fuel Injector: Diagrams Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 1 (2.7L/3.5L) - (ENGINE) 2 WAY Fuel Injector 2 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 2 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3862 Fuel Injector 3 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 3 (2.7L/3.5L) - (ENGINE) 2 WAY Fuel Injector 4 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 4 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3863 Fuel Injector 5 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 5 (2.7L/3.5L) - (ENGINE) 2 WAY Fuel Injector 6 (2.7L/3.5L) (Engine) 2 Way Connector (2.7L/3.5L) - (ENGINE) 2 WAY INJECTOR-FUEL 6 (2.7L/3.5L) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (2.7L/3.5L) (Engine) 2 Way > Page 3864 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal Fuel Injector: Service and Repair Fuel Injector - Removal 3.5L WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any part on the fuel system, the fuel system pressure must be released. 1. Release fuel pressure, See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect and isolate negative battery cable at battery. 3. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Removal. 4. Disconnect the quick connect fuel line from the fuel rail. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 3867 NOTE: Mark fuel injector electrical harness connectors with correct corresponding cylinder numbers. 5. Disconnect all fuel injector electrical connectors (1) from fuel injectors (2). 6. Remove fuel rail mounting bolts from fuel rail and lower intake manifold. NOTE: Gently rock the fuel rail and injectors back and forth to loosen the seals on the fuel injectors from the cylinder heads. CAUTION: Do Not use excessive force or prying tools to remove fuel rail and injectors. Damage to the fuel rail and injectors may result. 7. Lift fuel rail straight up off of the cylinder heads. 8. Drain any excess fuel from the fuel rail into an approved fuel storage container. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 3868 NOTE: When replacing individual fuel injectors, each fuel injector must be installed to it's original position. Mark or tag each fuel injector to identify the correct cylinder. 9. Remove retaining clips (5) from fuel injectors (2) at fuel rail (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 3869 Fuel Injector: Service and Repair Fuel Injector - Installation 3.5L NOTE: Inspect each O-ring seal on all the fuel injectors, replace O-ring seals if any damaged is noted. Note the fuel injector O-rings are color coded. The Blue colored O-ring is for the fuel rail side and the Green colored O-ring is cylinder head side. NOTE: If individual fuel injectors are being replaced, return the remaining fuel injectors to the original positions noted during removal. 1. Install and lubricate each fuel injector O-rings (1), (3) with a light drop of clean engine oil. 2. Install all of the fuel injectors (2) to the fuel rail (4), then install the retaining clip (5) to the fuel rail (4). 3. Inspect each fuel injector for proper installation. Note how the retaining clip (3) secures the fuel injector (1) to the fuel rail (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 3870 CAUTION: The fuel rail bolts are actually lower intake manifold bolts. These bolts must be torqued in a mandatory torque sequence. 4. Insert fuel injector nozzles into openings in the cylinder heads. Seat the injectors in place. Install the fuel rail bolts and tighten bolts in a mandatory torque sequence to 28 Nm (20.5 ft. lbs.). 5. Correctly position and connect the fuel injector electrical harness connectors to the fuel injectors. CAUTION: Make sure the fuel line quick connector is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle. 6. Connect quick connect fuel line to fuel rail. 7. Connect all fuel injector electrical connectors (1) to fuel injectors (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 3871 8. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 9. Connect the negative battery cable, tighten the nut to 5 Nm (45 in. lbs.). 10. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. DISCONNECTING WARNING: The fuel system is under a constant pressure (even with engine off). Before servicing any fuel system hose, fitting or line, fuel system pressure must be released. See: Fuel Filter/Fuel Pressure Release/Service and Repair CAUTION: Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. 1. Perform fuel pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting. 5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3875 6. Perform fuel pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 7. Disconnect negative battery cable from battery. 8. Clean fitting of any foreign material before disassembly. 9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. 10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3876 11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. 12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. 13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab. 14. Raise pull tab until it separates from quick-connect fitting. 15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3877 16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. a. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 17. Latch Clips Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. 18. Pry up on latch clip with a screwdriver (3). 19. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3878 20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 21. With special tool still inserted, pull fuel line from fuel rail. 22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 23. Disconnect quick-connect fitting from fuel system component being serviced. 24. Latch Clips Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. 25. Type 2: Separate and unlatch small arms on end of clip and swing away from fuel line. 26. Slide latch clip toward fuel rail while lifting with screwdriver. 27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 28. With special tool still inserted, pull fuel line from fuel rail. 29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 30. Disconnect quick-connect fitting from fuel system component being serviced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3879 31. Wing Type: A special tool is not necessary to disconnect this type of fitting (2). This line is used on different fuel and emission components. The graphic shows the fitting used on an EVAP canister. 32. Use two fingers to push on fitting wings (2) 33. Pull and disconnect fitting while holding wings. 34. After disconnection, locking fingers will remain within quick-connect fitting. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Fuel Flow Leakdown Less than 10 psi in 5 minutes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. FUEL PUMP OPERATION 1. Ignition on, engine not running. 2. With a scan tool, actuate the Fuel System test. NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly with no excessive noise. If the pump has excessive noise such as grinding, the pump should be replaced. CAUTION: Stop All Actuations. Does the Fuel Pump sound to be operate normally? Yes - Go to 2 No - Go to 7 2. FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge. 3. Ignition on, engine not running. 4. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Choose a conclusion that best matches your fuel pressure reading. Below Specification - Go to 3 Within Specification - Test Complete. Above Specification - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3886 Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special tool #6539 (5/16") or #6631(3/8") fuel line adapter and the fuel pressure gauge between the fuel supply line and the fuel pump module. 4. Ignition on, engine not running. 5. With the scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). CAUTION: Stop All Actuations. Is the fuel pressure within specification now? Yes - Repair/replace fuel supply line as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go to 5 No - Go to 6 5. CHECKING FUEL TANK SIPHON HOSE AND FUEL LINE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the Fuel Pump Module and the Fuel Tank Module. 3. Inspect the following fuel components: Fuel line and siphon hose between the Fuel Pump Module and the Fuel Tank Module. Look for disconnected and/or damaged lines or hoses. - Fuel Pressure Regulator not properly seated in the module. Were the above items in good working condition? Yes - Go to 6 No - Repair or replace as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. CHECKING THE FUEL PUMP INLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3887 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Inlet and the bottom of the fuel tank for debris that could cause the fuel pump inlet to be plugged. Is the Fuel Pump Inlet plugged? Yes - Repair/Replace as necessary. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. FUEL PUMP MOTOR GROUND CIRCUIT 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light to battery voltage, probe the Fuel Pump Motor Ground circuit in the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Does the test light illuminate brightly. Yes - Replace the Fuel Pump Module. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Repair the Fuel Pump Motor Ground circuit. - Perform the PCM Verification TestSee: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3888 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3889 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3890 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3891 Fuel Pressure: Testing and Inspection Fuel Delivery System Output - Flow Test FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure. - Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. - Use extreme caution when connecting and disconnecting fuel lines. Considerable fuel leakage may occur when servicing the fuel system. Wear protective eyewear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair or replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester 8978A. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3892 Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly 8978A-1 Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: - Open the Fuel System Isolation Valve (1). - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3893 - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 1. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. 2. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa ± 34 kPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 kPa ± 34 kPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Ignition on, engine not running. 2. With the scan tool, actuate the fuel pump. 3. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. 4. Turn the ignition off. 5. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. Does the amount of fuel in the reservoir meet or exceed the specification? Yes - Test complete. No - Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal Fuel Rail: Service and Repair Fuel Rail - Removal 3.5L WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any part on the fuel system, the fuel system pressure must be released. 1. Release fuel pressure See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect and isolate negative battery cable. 3. Remove the upper intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 4. Disconnect the quick connect fuel line from the fuel rail See: Fuel Line Coupler/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3898 NOTE: Mark fuel injector electrical harness connectors with correct corresponding cylinder numbers. 5. Disconnect all fuel injector electrical connectors (1) from fuel injectors (2). 6. Remove fuel rail mounting bolts from fuel rail and lower intake manifold. NOTE: Gently rock the fuel rail and injectors back and forth to loosen the seals on the fuel injectors from the cylinder heads. CAUTION: Do Not use excessive force or prying tools to remove fuel rail and injectors. Damage to the fuel rail and injectors may result. 7. Lift fuel rail straight up off of the cylinder heads. 8. Drain any excess fuel from the fuel rail into an approved fuel storage container. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3899 NOTE: Mark or tag each fuel injector with correct corresponding cylinder numbers 9. Remove retaining clips (5) from fuel injectors (2) at fuel rail (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3900 Fuel Rail: Service and Repair Fuel Rail - Installation 3.5L NOTE: Inspect each O-ring seal on all the fuel injectors, replace O-ring seals if any damaged is noted. Note the fuel injector O-rings are color coded. The Blue colored O-ring is for the fuel rail side and the Green colored O-ring is cylinder head side. 1. Install and lubricate each fuel injector O-rings (1), (3) with a light drop of clean engine oil. 2. Install all of the fuel injectors (2) to the fuel rail (4), then install the retaining clips (5) to the fuel rail (4). 3. Inspect each fuel injector for proper installation. Note how the retaining clip (3) secures the fuel injector (1) to the fuel rail (2). CAUTION: The fuel rail bolts are actually lower intake manifold bolts. These bolts must be torqued in a mandatory torque sequence. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3901 4. Insert fuel injector nozzles into openings in the cylinder heads. Seat the injectors in place. Install the fuel rail bolts and tighten bolts in a mandatory torque sequence to 28 Nm (20.5 ft. lbs.). 5. Correctly position and connect all fuel injector electrical connectors (1) to fuel injectors (2). CAUTION: Make sure the fuel line quick connector is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle. 6. Connect quick connect fuel line to fuel rail See: Fuel Line Coupler/Service and Repair. 7. Install upper intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 8. Connect the negative battery cable, tighten the nut to 5 Nm (45 in. lbs.). 9. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tube(s) - Removal Fuel Supply Line: Service and Repair Fuel Tube(s) - Removal 3.5L WARNING: The fuel system is under constant pressure even with engine off. Until the fuel pressure has been properly relieved from the system, do not attempt to open the fuel system. 1. Release the fuel system pressure See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect and isolate negative battery cable. 3. Disconnect the fuel line quick connect fitting (2) from the body mounted fuel line bundle See: Fuel Line Coupler/Service and Repair. 4. Disconnect the fuel line quick connect fitting (3) from the fuel rail See: Fuel Line Coupler/Service and Repair. 5. Remove the fuel line (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tube(s) - Removal > Page 3906 Fuel Supply Line: Service and Repair Fuel Tube(s) - Installation 3.5L 1. Install fuel line quick connect fitting (3) to fuel rail See: Fuel Line Coupler/Service and Repair. 2. Install fuel line quick connect fitting (2) to body mounted fuel line bundle See: Fuel Line Coupler/Service and Repair. 3. Connect the negative battery cable, tighten the nut to 5 Nm (45 in. lbs.). 4. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3916 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3917 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3923 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3924 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal Fuel Filler Neck: Service and Repair Removal AWD 1. Disconnect and isolate negative battery cable at battery. 2. Remove fuel cap. 3. Remove the inner splash shield, See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 4. Disconnect the quick connect fitting (1) and remove the canister filter line See: Fuel Line Coupler/Service and Repair. 5. Disconnect the quick connect fitting (2) and remove the recirculation line See: Fuel Line Coupler/Service and Repair. 6. Loosen the hose clamp and remove the fuel filler tube (3) from the fuel tank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3927 7. Remove filler tube mounting bracket bolt (1) from bracket (2) and body mount (3). 8. Remove fuel filler tube (2) from the fuel door housing assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3928 Fuel Filler Neck: Service and Repair Installation AWD 1. Install fuel filler tube (2) to the fuel door housing assembly (1). 2. Install fuel filler tube (3) to the fuel tank. Tighten hose clamp to 3 Nm (27 in. lbs.). 3. Install the recirculation line quick connect fitting (2) to the fuel tank. 4. Install the canister filter line quick connect fitting (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3929 5. Install filler tube mounting bracket (2) and bolt (1) to the body mount (3). Tighten to 11.5 Nm (101 in. lbs.). 6. Install the inner splash shield, See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 7. Install fuel cap. 8. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 3934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 3935 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 3936 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 3939 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3942 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3943 Fuel Gauge Sender: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Service and Repair/Removal and Replacement/Fuel Tank Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3946 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3947 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3948 1. Drain and remove the fuel tank See: Service and Repair/Removal and Replacement/Fuel Tank Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3949 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3950 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3951 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3952 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3953 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3954 Fuel Gauge Sender: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Pump Module - Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3955 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3956 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Pump Module - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3965 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3966 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3972 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3973 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3978 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3979 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 3982 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 3987 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3993 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Auto Shutdown Relay > Page 3994 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way Main Relay (Computer/Fuel System): Diagrams Auto Shutdown Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-AUTO SHUT DOWN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Diagrams > Auto Shutdown Relay (In TIPM) 5 Way > Page 3997 Main Relay (Computer/Fuel System): Diagrams PCM Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-PCM - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4002 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Raise vehicle on hoist. 2. Position an oil collecting container under switch location. 3. Disconnect electrical connector (1). 4. Remove the oil pressure switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 4007 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION 1. Apply Mopar(R) Thread Sealant to the switch threads. 2. Install oil pressure switch (2). 3. Connect electrical connector (1). 4. Lower vehicle. 5. Start engine and check for leaks. 6. Check engine oil level and adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 4011 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 4012 Throttle Body: Diagrams Connector (2.7L/3.5L) - (ENGINE) 6 WAY THROTTLE BODY (2.7L/3.5L) - (ENGINE) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal Throttle Body: Service and Repair Throttle Body - Removal 3.5L 1. Disconnect and isolate negative battery cable at battery. 2. Remove engine cover. 3. Remove clean air hose from throttle body. 4. Disconnect electrical connector (1) from throttle body. 5. Remove nut (1) form throttle body bracket (2). 6. Remove bolt (3) and throttle body bracket (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 4015 7. Remove bolts (2), stud (1) and remove throttle body from intake manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 4016 Throttle Body: Service and Repair Throttle Body - Installation 3.5L NOTE: Make sure the intake gasket is clean and free of debris. Inspect the intake gasket for damage. Replace as necessary. CAUTION: DO NOT OVER TORQUE. Over tightening can cause damage to the throttle body, gaskets, bolts and/or the intake manifold. 1. Install throttle body, gasket and bolts to intake manifold. 2. Install throttle body and three throttle body bolts (2), and stud (1). Hand tighten the three bolts and one stud. CAUTION: The throttle body must be torqued in a mandatory torque sequence. Tighten in a criss cross pattern to specification. 3. Tighten the three bolts and one stud in a mandatory torque criss - cross pattern sequence to 5.5 Nm (50 in. lbs.). 4. Install throttle body bracket (2), nut (1) and bolt (3). Tighten nut (1) to 12 Nm (106 in. lbs.). Tighten bolt (3) to 28 Nm (20.5 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 4017 5. Connect electrical connector (1) to throttle body. 6. Install clean air hose to throttle body. 7. Install engine cover. 8. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 9. Use a scan tool and perform the ETC RELEARN function. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Locations Variable Induction Control Solenoid: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Locations > Page 4022 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Locations > Page 4023 Variable Induction Control Solenoid: Diagrams Connector (3.5L) - (ENGINE) 6 WAY SOLENOID-SHORT RUNNER VALVE (3.5L) - (ENGINE) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 4027 Variable Induction Control Valve: Diagrams Connector (3.5L) - (ENGINE) 6 WAY SOLENOID-MANIFOLD TUNING VALVE (3.5L) - (ENGINE) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal Variable Induction Control Valve: Service and Repair Removal Short Runner Valve REMOVAL 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Unlock and disconnect electrical connector. 4. Remove four mounting screws. 5. Remove Short Runner Valve. 6. Remove and inspect o-ring. Manifold Tuning Valve 3.5L Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 4030 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the electrical connector. 4. Remove the 4 mounting bolts. 5. Pull manifold tune valve (MTV) straight out of manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 4031 6. Be sure the O-ring (1) is still in place on the MTV shaft. If not, refer to the following step. 7. If O-ring is not on MTV shaft (from previous step), gently pry it (1) from intake manifold. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 4032 Variable Induction Control Valve: Service and Repair Installation Short Runner Valve INSTALLATION 1. Install o-ring. 2. Align tab on valve to slot in manifold and install. 3. Install mounting screws. 4. Tighten bolts to 2.8 Nm (25 in. lbs.). 5. Connect electrical connector and lock. 6. Install engine cover. 7. Connect negative battery cable. Manifold Tuning Valve 3.5L Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 4033 NOTE: Inspect the O-ring and gasket for the manifold tune valve replace if damaged. 1. Install a new O-ring and gasket to the manifold tune valve, if necessary. 2. Install the manifold tuning valve. 3. Make sure that the alignment pin and notch line up. 4. Install bolts and tighten. 5. Connect the electrical connector. 6. Install the engine cover. 7. Connect negative battery cable and tighten to 16.5 Nm (145 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 2.4L The firing order is 1-3-4-2. 3.5L The firing order is 1-2-3-4-5-6. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 4042 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4043 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4044 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 4047 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations Condenser: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations > Page 4051 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations > Page 4052 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations > Page 4053 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations > Page 4054 Condenser: Diagrams Connector (GAS) - (ENGINE) 1 WAY CAPACITOR-IGNITION 1 (GAS) - (ENGINE) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Ignition Capacitor - Removal Condenser: Service and Repair Ignition Capacitor - Removal 3.5L The ignition capacitor is located on the drivers side of the engine. 1. Disconnect and isolate negative battery cable at battery. 2. Remove electrical connector (3). 3. Remove mounting bolt (1) and ignition capacitor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Ignition Capacitor - Removal > Page 4057 Condenser: Service and Repair Ignition Capacitor - Installation 3.5L 1. Install ignition coil capacitor (2) and bolt (1). 2. Tighten bolt to 28 Nm (20.5 ft. lbs.). 3. Connect electrical connector (3). 4. Connect negative battery cable and tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4061 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4062 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4065 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications IGNITION RESISTANCE IGNITION COIL RESISTANCE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4071 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4072 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4073 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4074 Ignition Coil: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4075 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4076 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4077 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4078 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (Gas) > Page 4079 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way Ignition Coil: Diagrams Ignition Coil 1 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 1 (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4082 Ignition Coil: Diagrams Ignition Coil 2 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 2 (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4083 Ignition Coil: Diagrams Ignition Coil 3 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 3 (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4084 Ignition Coil: Diagrams Ignition Coil 4 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 4 (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4085 Ignition Coil: Diagrams Ignition Coil 1 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 1 (GAS) - (ENGINE) 3 WAY Ignition Coil 2 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 2 (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4086 Ignition Coil 3 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY COIL-IGNITION 3 (GAS) - (ENGINE) 3 WAY Ignition Coil 4 (Gas) (Engine) 3 Way Connector (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4087 COIL-IGNITION 4 (GAS) - (ENGINE) 3 WAY Ignition Coil 5 (2.7L/3.5L) 3 Way Connector (2.7L/3.5L) - (ENGINE) 3 WAY COIL-IGNITION 5 (2.7L/3.5L) - (ENGINE) 3 WAY Ignition Coil 6 (2.7L/3.5L) 3 Way Connector (2.7L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Gas) (Engine) 3 Way > Page 4088 COIL-IGNITION 6 (2.7L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4089 Ignition Coil: Testing and Inspection CHECKING THE IGNITION COIL OPERATION For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. IGNITION COIL WIRING OR CONNECTORS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4090 NOTE: Diagnose and repair any ignition coil, CMP sensor, or CKP sensor DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Ignition Coil for the cylinder being tested and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. NOTE: If the vehicle is not equipped with the coil on plug ignition system, check the resistance of the ignition wire(s) before checking the cylinder with a spark tester. The resistance should be below 10k Ohms. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. IGNITION COIL OPERATION NOTE: Inspect the ignition coil for damage, carbon tracking on the coil or a damaged spark plug insulator boot. If a problem is found, replace the ignition coil. NOTE: 6.1L coils must have a spark tester installed on both sides of the coil during the following test. During the test, each side of the coil should output a crisp blue spark that is able to jump the gap of the spark tester. NOTE: On the 2.7 and 3.5 engines, cylinders 1, 3 and 5, it is necessary to remove the upper intake manifold to access the ignition coils. Once the ignition coil has been removed, the intake must be installed in order to crank the engine. Move the ignition coil harness connector through the slots in the upper intake and then connect the coil to the harness connector. Secure the upper intake to the lower intake. 1. Turn the ignition off. 2. If the vehicle is equipped with coil on plug ignition system, remove the ignition coil for the cylinder being tested. 3. Disconnect the fuel injector harness connector for the cylinder being tested. 4. For coil on plug ignition systems, install a spark tester(s) on the ignition coil, otherwise install the spark tester to the ignition wire. 5. While cranking the engine observe the spark coming from the spark tester. NOTE: A crisp blue spark that jumps the gap of the spark tester should be generated. Is good spark present? Yes - Go To 7 No - Go To 3 3. MAIN/ASD RELAY OUTPUT CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Ignition Coil harness connector. 3. Turn the ignition on. 4. With the scan tool, actuate the Main/ASD Relay to on. 5. Using a 12-volt test light connected to ground, check the Main/ASD Relay output circuit in the ignition coil harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright during the actuation? Yes Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4091 - Go To 4 No - Repair the Main/ASD Relay output circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 4. IGNITION COIL WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Using a 12-volt test light connected to 12 volts, check the Ignition Coil control circuit for the cylinder being tested in the Ignition Coil harness connector. 2. Crank the engine for 5 seconds. NOTE: The test light should blink each time the circuit is activated by the PCM. Does the test light blink each time the circuit is activated by the PCM? Yes - Replace the Ignition Coil. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 5 5. IGNITION COIL CONTROL CIRCUIT OPEN OR HIGH RESISTANCE CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals, resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Measure the resistance of the Ignition Coil control circuit for the cylinder being tested between the Ignition Coil harness connector and the appropriate terminal of PCM Pinout Box 8815. Is the resistance below 5.0 Ohms? Yes - Go To 6 No - Repair the Ignition Coil control circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 6. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Ignition Coil for the cylinder being tested and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Perform any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4092 No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 7. SPARK PLUG(S) 1. Turn the ignition off. 2. Remove the spark plug. NOTE: Vehicles equipped with 5.7L or 6.1L engines must have both spark plugs (per cylinder) removed and inspected to ensure proper operation. 3. Inspect the spark plug for any of the following conditions: Cracks or damage - Carbon tracking - Foreign material - Gap not within specification - Loose or broken electrode NOTE: Lightly tap the bottom of the spark plug on a solid surface. The electrode in the spark plug should not move. Were any problems found? Yes - Replace the spark plug. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Test Complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil - Removal Ignition Coil: Service and Repair Ignition Coil - Removal 3.5L 1. Remove engine cover. 2. Disconnect and isolate the negative battery cable. 3. Remove the upper intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 4. Unlock and disconnect electrical connector (2) from ignition coils. 5. Remove mounting bolts and engine cover studs (1). CAUTION: Prior to removing the ignition coils, spray compressed air around the coils and spark plugs. If dirt and debris enter the engine, this may cause internal engine damage. 6. Twist, lift and remove ignition coil from engine. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil - Removal > Page 4095 Ignition Coil: Service and Repair Ignition Coil - Installation 3.5L 1. Install ignition coil (1). 2. Install engine cover studs (1) in the two outside ignition coils on the front of the engine. Install bolts on the other ignition coils. 3. Tighten studs and bolts to 8 Nm (71 in. lbs.). 4. Connect electrical connector and lock (2). 5. Install intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 6. Connect negative battery cable and tighten nut to 5 Nm (45 in. lbs.). 7. Install engine cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4099 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4100 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 4103 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1/1 (2.4L/3.5L) > Page 4109 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4110 Camshaft Position Sensor: Diagrams Connector (2.4L/3.5L) - (ENGINE) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (2.4L/3.5L) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4111 Camshaft Position Sensor: Description and Operation CAMSHAFT AND CRANKSHAFT SIGNALS 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 3.5L 1. Disconnect and isolate the negative battery cable at battery. 2. Disconnect electrical connector (3) from camshaft position (CMP) sensor (2). 3. Remove bolt (1) and CMP sensor (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 4114 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 3.5L CAUTION: Install camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all. NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated. 2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 Nm (106 in. lbs.). 3. Connect and lock the electrical connector (3) to the CMP sensor (2). 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4118 Crankshaft Position Sensor: Diagrams Connector (GAS) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (ENGINE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4119 Crankshaft Position Sensor: Description and Operation OPERATION 4 CYLINDER CAM AND CRANK SIGNALS NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. 6 CYLINDER CAM AND CRANK SIGNALS Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 3.5L NOTE: The crankshaft position sensor is located on the driver side of the vehicle, above the differential housing. The bottom of the sensor sits above the drive plate. 1. Disconnect and isolate the negative battery cable. 2. Unlock and disconnect the electrical connector from the crankshaft position sensor. 3. Remove the sensor mounting screw and the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4122 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 3.5L NOTE: If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor. 1. Push the crankshaft position (CKP) sensor into the transmission case with a twisting motion until fully seated. CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the mounting surface. If the sensor is not flush, damage to the sensor mounting tang may result. 2. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.). 3. Connect and lock the electrical connector to the CKP sensor. 4. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.). NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations Ignition Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations > Page 4126 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Ignition Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Ignition Switch: Connector Views Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 4146 Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Operation OPERATION Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a spring-loaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY,""RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS) Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Operation. REMOTE KEYLESS ENTRY (RKE) The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Operation TIRE PRESSURE MONITORING (TPM) The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Operation. REMOTE START WITH/EXTENDED RANGE ANTENNA Further information concerning the Remote Start System. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Starting System/Description and Operation/Starting System - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI) The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. PARK SHIFT INTERLOCK The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 4147 Ignition Switch: Description and Operation Ignition Switch - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN). The WIN, along with the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch located on the face of the instrument panel just to the inboard side of the steering column. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. In addition to replacing a conventional keyed ignition switch, the WIN is an integrated electronic receiver that serves as the base station in the vehicle. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) RF communication. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged the entire WIN must be replaced See: Service and Repair/Wireless Ignition Node Receiver - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ignition Switch: Symptom Related Diagnostic Procedures FOBIK TRAPPED IN WIN The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 5. Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. 6. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. 7. Remove the lower WIN attaching screw (5). 8. Remove the lower WIN bracket attaching screw (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 4152 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 4153 Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Installation INSTALLATION NOTE: The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening. 2. Install the lower WIN bracket attaching screw (4). 3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 4154 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Install knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker Installation. 9. Connect negative battery cable. 10. If necessary, program the WIN, See: Computers and Control Systems/Testing and Inspection/Programming and Relearning. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4158 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4159 Knock Sensor: Diagrams Connector (GAS) - (ENGINE) 2 WAY SENSOR-KNOCK (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 3.5L 1. Disconnect the negative battery cable. 2. Remove the upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Removal. 3. Disconnect the electrical connector. 4. Remove the knock sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 4162 Knock Sensor: Service and Repair Knock Sensor - Installation 3.5L CAUTION: Always use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control. 1. Install knock sensor. Tighten knock sensor to 20 Nm (15 ft. lbs.). 2. Route the knock sensor wire in the proper location. 3. Install upper intake manifold, See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold - Installation. 4. Connect the electrical connector. 5. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal Spark Plug Tube: Service and Repair Removal REMOVAL 1. Remove cylinder head cover(s). See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal 2. Using suitable locking pliers, remove the tube (1) from the cylinder head and discard tube. 3. Clean area around spark plug with Mopar(R) Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Spark Plug Tube > Component Information > Service and Repair > Removal > Page 4168 Spark Plug Tube: Service and Repair Installation INSTALLATION 1. Apply Mopar(R) Stud and Bearing Mount to a new tube (1) approximately 1 mm (0.039 in.) from the end of tube, in a 3 mm (0.118 in.) wide area. 2. Install sealer end of tube (1) into the cylinder head. Then carefully install the tube (1) using a hardwood block and mallet. Install the tube (1) until it is seated into the bottom of the bore. 3. For spark plug tube (1) seal replacement, See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 4. Install cylinder head cover(s). See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation - INSTALLATION) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4175 Pressure Regulating Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4178 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove shift cable (1) from manual lever (2). NOTE: Keep the Top Sound Dampener Cover if replacing the unit 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4179 10. Remove the top valve body oil pan (1) bolts. 11. Remove the solenoid pack connector (2) at valve body oil pan (1). 12. Raise the vehicle on a hoist. 13. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4180 14. Turn the wheel (3) fully to the left. 15. Remove the bolt (2) at the ground cable (3). 16. Remove the clip (1) at the valve body pan. 17. Move cable away from the valve body pan. 18. Remove the pressure tap plug (2) at valve body oil pan. 19. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 20. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4181 21. Remove the bolts (1) at the line pressure sensor. 22. Remove the line pressure sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4182 Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Installation INSTALLATION 1. Install the line pressure sensor on to the valve body. 2. Install the bolts (1) to the line pressure sensor and tighten to 6 Nm (50 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle on a hoist. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4183 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise the vehicle on the hoist. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4184 11. Install the clip to the valve body oil pan 12. Install the Front Sound Damper Cover (2) and install the fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4185 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4186 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4187 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4188 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove the shift cable (1) from the manual lever (2). 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). 10. Remove shift cable (1) from manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4189 11. Remove the top valve body oil pan (1) bolts. 12. Remove the solenoid pack connector (2) at valve body oil pan (1). 13. Raise the vehicle on a hoist. 14. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4190 15. Turn the wheel (3) fully to the left. 16. Remove the bolt (2) at the ground cable (3). 17. Remove the clip (1) at the valve body pan. 18. Move cable away from the valve body pan. 19. Remove the pressure tap plug (2) at valve body oil pan. 20. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 21. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4191 22. Remove the bolt (1) at the pressure control solenoid. 23. Remove the pressure control sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4192 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Installation INSTALLATION 1. Install the pressure control solenoid on to the valve body. 2. Install the bolts (1) to the pressure control solenoid and tighten to 6 Nm (40 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4193 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise and support the vehicle. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4194 11. Install the clip to the valve body oil pan. 12. Install the Front Sound Damper Cover (2) and fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4195 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4196 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4200 Shift Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Removal REMOVAL 1. Remove valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4203 Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the center floor console to access the gear selector unit. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Firmly grasp the socket (1) on the side of the gear selector housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the shifter housing. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal > Page 4210 Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the socket (1) on the side of the gear selector housing. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening in the side of the gear selector housing. 4. Insert the bulb and socket into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the center floor console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Locations > Page 4214 Transmission Mode Indicator - A/T: Diagrams Connector - (BODY) 3 WAY LAMP-PRNDL - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure Control Module: Service and Repair Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure > Page 4221 Control Module: Service and Repair Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4226 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4229 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the all-wheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4230 provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction control. It only works on situations where front-to-rear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Remove the left front trim panel. 2. Remove the electrical connector. 3. Remove the mounting nuts. 4. Remove the ECC module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 4233 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Install ECC module into mounting studs. 2. Install mounting nuts and tighten to 8 Nm (71 in. lbs.) torque. 3. Install the electrical connector. 4. Install the left front trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Removal REMOVAL 1. Remove valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4240 Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4244 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4247 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4248 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4249 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4250 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4251 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4256 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4257 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-INPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4260 Transmission Speed Sensor: Diagrams Output Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-OUTPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4261 Transmission Speed Sensor: Diagrams Transfer Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-TRANSFER SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4264 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Operation OPERATION The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4265 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4266 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4267 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Output Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4268 The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4269 NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Transfer Shaft Speed Sensor - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4270 The Transfer Shaft Speed Sensor (3) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Transfer Shaft Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Transfer Shaft Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4271 The transfer shaft speed sensor (3) is located at the rear of the case (backside). It reads rotation of the front annulus/rear carrier assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4274 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4275 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4276 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4277 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4278 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4279 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Output Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4280 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4281 Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Input Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4282 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4283 Transfer Shaft Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the transfer shaft sensor (3). 2. Remove the bolt at transfer shaft sensor (1). 3. Pull up on transfer shaft sensor to remove. Transfer Shaft Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4284 1. Install a new O-ring (2). on the transfer shaft speed sensor (1). 2. Install transfer shaft speed sensor (3) into case. 3. Install bolt at transfer shaft speed sensor (1) and tighten to 12 Nm (105 in. lbs.). 4. Reconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4293 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4294 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4295 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4296 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4297 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4298 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4299 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4300 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4301 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4302 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4303 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function PROM - Programmable Read Only Memory: Customer Interest Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 4309 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 4314 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition PROM - Programmable Read Only Memory: Customer Interest Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 4319 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 4324 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-09C > Jun > 09 > Engine Controls - MIL ON/DTC P0452 Set In Memory PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0452 Set In Memory NUMBER: 18-003-09 REV. C GROUP: Vehicle Performance DATE: June 11, 2009 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-003-09 REV. B, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL VEHICLE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Driveability Improvements Or MIL Illumination Diagnostic Trouble Code P0452 Evap Pressure Switch Stuck Closed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2008 (CS) Pacifica** 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 - 2009 (RT) Town & Country/Voyager/Caravan (Includes International Markets) NOTE: This bulletin applies to: - **2008 CS vehicles equipped with a 4.0L Engine (Sales Code EGO)**. - 2007, 2008 JS vehicles equipped with a 2.4L Engine and Automatic Transmission (Sales Code EDG or ED3 with DFF) built before June 19, 2008 - 2007, 2008 and 2009 JS vehicles equipped with a 2.7L and 3.5L engine (sales code EER or EGF) built Before October 15, 2008 (MDH 1015XX) - 2008 RT vehicles equipped with a 3.3L or 3.8L or 4.0L engine (sales code EGV, EGL or EGQ) - 2009 RT vehicles equipped with a 3.3L or 3.8L or 4.0L engine (sales code EGV, EGL or EGQ built before May 11, 2009 (MDH 0511XX). - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before August 20, 2008 (MDH 0820XX) - 2009 JC vehicles equipped with a 3.5L engine (sales code EGF) built before September 6, 2008 (MDH 0906XX) SYMPTOM/CONDITION: Some customers may complain that the engine stumbles, runs rough, has idle fluctuations and/or surges at idle or there is a MIL illumination. Further investigation by the technician may find DTC: - P0452 - Evap Pressure Switch Stuck Closed DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-09C > Jun > 09 > Engine Controls - MIL ON/DTC P0452 Set In Memory > Page 4329 further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer to Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. Clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. c. Perform the Quick Learn function, found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine PROM - Programmable Read Only Memory: Customer Interest Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 4334 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 4340 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 4345 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 4350 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 4355 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-003-09C > Jun > 09 > Engine Controls - MIL ON/DTC P0452 Set In Memory PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0452 Set In Memory NUMBER: 18-003-09 REV. C GROUP: Vehicle Performance DATE: June 11, 2009 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-003-09 REV. B, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL VEHICLE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Driveability Improvements Or MIL Illumination Diagnostic Trouble Code P0452 Evap Pressure Switch Stuck Closed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2008 (CS) Pacifica** 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 - 2009 (RT) Town & Country/Voyager/Caravan (Includes International Markets) NOTE: This bulletin applies to: - **2008 CS vehicles equipped with a 4.0L Engine (Sales Code EGO)**. - 2007, 2008 JS vehicles equipped with a 2.4L Engine and Automatic Transmission (Sales Code EDG or ED3 with DFF) built before June 19, 2008 - 2007, 2008 and 2009 JS vehicles equipped with a 2.7L and 3.5L engine (sales code EER or EGF) built Before October 15, 2008 (MDH 1015XX) - 2008 RT vehicles equipped with a 3.3L or 3.8L or 4.0L engine (sales code EGV, EGL or EGQ) - 2009 RT vehicles equipped with a 3.3L or 3.8L or 4.0L engine (sales code EGV, EGL or EGQ built before May 11, 2009 (MDH 0511XX). - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before August 20, 2008 (MDH 0820XX) - 2009 JC vehicles equipped with a 3.5L engine (sales code EGF) built before September 6, 2008 (MDH 0906XX) SYMPTOM/CONDITION: Some customers may complain that the engine stumbles, runs rough, has idle fluctuations and/or surges at idle or there is a MIL illumination. Further investigation by the technician may find DTC: - P0452 - Evap Pressure Switch Stuck Closed DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-003-09C > Jun > 09 > Engine Controls - MIL ON/DTC P0452 Set In Memory > Page 4360 further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer to Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. Clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. c. Perform the Quick Learn function, found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4365 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4366 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4367 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4368 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4369 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4370 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4371 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4372 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4373 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4374 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4375 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 4380 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - PCM Update For Cruise Control Function NUMBER: 18-028-10 GROUP: Vehicle Performance DATE: October 16, 2010 HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 11.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Speed Control Operation Improvements OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009-2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring/Sebring Convertible 2008 - 2010 (RI) Town & Country/Grand Voyager NOTE: This bulletin applies to RT vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 15, 2010 (MDH 091 5XX). NOTE: This bulletin applies to JC vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 28, 2010 (MDH 0928XX). NOTE: This bulletin applies to JS vehicles equipped with a 6-speed automatic transmission (sales code DG2) built before September 23, 2010 (MDH 0923XX). SYMPTOM/CONDITION: The speed control operation has changed to correct the following conditions: i. Adjust the set speed control to react when the speed drops to 2-3 MPH below the target. ii. A RPM increase while going downhill due to a transmission downshift. DIAGNOSIS: Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-10 > Oct > 10 > Engine Controls - PCM Update For Cruise Control Function > Page 4386 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function, found in the Misc Function menu for the TCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2181 Is Stored In Memory NUMBER: 18-015-10 REV C GROUP: Vehicle Performance DATE: August 12 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-015-10 REV B, DATED JULY *, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL VEHICLE MODELS THE WiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs HELP USING THE WiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE WiTECH DIAGNOSTIC APPLICATION WINDOW THE WiTECH SOFTWARE LEVEL MUST BE AT RELEASE 1101 OR HIGHER TO PERFORM THIS PROCEDURE StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE SUBJECT: Flash: MIL Illumination For P2181 - Cooling System Performance OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software MODELS: 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 (JK) Wrangler **2008 - 2010 (K1) Cherokee (CKD)** 2009 (LC) Challenger 2007 - 2010 (LE) 300C/300C Touring (International Markets) 2007 - 2010 (LX) 300/300 C/Charger/Magnum 2007 - 2009 (L2) 300 (China) 2008 - 2009 (RT) Town & Country/Grand Voyager 2008 - 2009 (WK) Grand Cherokee 2008 - 2009 (WH) Grand Cherokee (International Markets) 2008 - 2009 (XK) Commander 2008 - 2009 (XH) Commander (International Markets) NOTE: This bulletin applies to RT vehicles built with a 3.3L, 3.8L or 4.0L engine (Sales Codes EGV, EGL or EGQ) NOTE: This bulletin applies to WK/WH/XK/HX vehicles equipped with a 4.7L or 5.7L engine (Sales code EVE or EZB/EZH/EZD) and a automatic transmission (Sales code DGJ or DGQ) NOTE: This bulletin applies to JC and JS vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGF) and a automatic transmission NOTE: **This bulletin applies to LC/LE/LX/L2 vehicles equipped with a 2.7L or 3.5L engine (Sales code EER or EGG) and a 4-speed automatic transmission (sales code DGV).** NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-10C > Aug > 10 > Engine Controls - MIL ON/DTC P2181 Is Stored In Memory > Page 4391 This bulletin applies to JK vehicles equipped with a 3.8L engine (Sales code EGT) NOTE: **This bulletin applies to K1 vehicles equipped with a 3.7L engine (Sales code EKG)** SYMPTOM/CONDITION: Some customers may complain of a MIL illumination Upon further investigation the Technician may find that P2181 Cooling System Performance has been set. DIAGNOSIS: Using a Scan Tool (WiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT verify all engine systems are functioning as designed If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted the flash should be restarted. 1. Reprogram the PCM with the latest software Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 Electrical > Electronic Control Modules Service Information > Module Powertrain Control > Standard Procedures > PCM/ECM Programming Gas After PCM reprogramming the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming The WiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. On 62TE equipped vehicles clear the Variable Line Pressure (VLP) Counters found in the Misc Function menu for the PCM ECU. c. Perform the Quick Learn function found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label ** POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update For Over-Rev Condition NUMBER: 18-019-10 GROUP: Vehicle Performance DATE: June 3, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-09 REV. A, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS UPDATE INCLUDES ADDITIONAL BODIES AND ENHANCED SOFTWARE FOR ALL VEHICLES EXCEPT THE RT BODIES. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Engine Over Rev Condition OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) or for vehicles equipped with a 2.8L turbo diesel engine the Transmission Control Module (1CM) with new software. MODELS: **2008 (CS) Pacifica** 2008 - 2009 (RT) Town & Country/Grand Voyager (International Markets) 2009 (RT) Town & Country/Grand Voyager** **2009 - 2010 (JC) Journey** **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin applies: 1. **2008 CS vehicles built with a 4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2).** 2. 2008 and 2009 RT vehicles built with a 2.8L engines (Sales Codes ENS) and a 62TE automatic transmission (sales code DG2) built before March 24, 2009 (MDH 0324XX). 3. 2009 RT vehicles built with a 3.8L/4.0L engines (Sales Codes EGL or EGQ) and a 62TE automatic transmission (sales code DG2) built before May 11, 2009 (MDH 0511XX), 4. 2009 JC vehicles built with a 2.7L/3.5L engines (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2). 5.**201 0 JC International vehicles only built with a 2.7L engine (sales code EER) and a 62TE automatic transmission (sales code DG2) built before May 11, 2010 (MDH 0511XX).** 6.**2007 - 2009 JS vehicles built with a 2.7L/3.5L engine (sales code EER or EGF) and a 62TE automatic transmission (sales code DG2).** SYMPTOM/CONDITION: Some customers may notice that the engine can achieve higher RPM's than normal after an unusual shift condition. This condition can happen if the driver of the vehicle shifted the vehicle from drive to neutral then back to drive (D-N-D) with their foot on the accelerator while driving at interstate highway speeds. The updated software corrects this condition. DIAGNOSIS: Using a Scan Tool (wiTECH or StarMOBILE) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-019-10 > Jun > 10 > Engine Controls - ECM Update For Over-Rev Condition > Page 4396 functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear the Variable Line Pressure (VLP) Counters, found in the wiTECH Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. b. Clear any DTC's that may have been set in other modules due to reprogramming. c. Perform the Quick Learn function, found in the wiTECH Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0420/P0430 Set NUMBER: 18-026-09 GROUP: Vehicle Performance DATE: September 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P0420 And/Or P0430 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to JC vehicles equipped with a 3.5L engine and (Sales code EGF) and a 62TE automatic transmission (sales code DG2). SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that P0420 - Catalyst Efficiency (Bank 1) and/or P0430 - Catalyst Efficiency (Bank2) has been set. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present other then the ones listed above record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control> Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-026-09 > Sep > 09 > Engine Controls - MIL ON/DTC's P0420/P0430 Set > Page 4401 Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-003-09C > Jun > 09 > Engine Controls - MIL ON/DTC P0452 Set In Memory PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0452 Set In Memory NUMBER: 18-003-09 REV. C GROUP: Vehicle Performance DATE: June 11, 2009 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-003-09 REV. B, DATED MAY 29, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL VEHICLE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Driveability Improvements Or MIL Illumination Diagnostic Trouble Code P0452 Evap Pressure Switch Stuck Closed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2008 (CS) Pacifica** 2009 (JC) Journey 2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible 2008 - 2009 (RT) Town & Country/Voyager/Caravan (Includes International Markets) NOTE: This bulletin applies to: - **2008 CS vehicles equipped with a 4.0L Engine (Sales Code EGO)**. - 2007, 2008 JS vehicles equipped with a 2.4L Engine and Automatic Transmission (Sales Code EDG or ED3 with DFF) built before June 19, 2008 - 2007, 2008 and 2009 JS vehicles equipped with a 2.7L and 3.5L engine (sales code EER or EGF) built Before October 15, 2008 (MDH 1015XX) - 2008 RT vehicles equipped with a 3.3L or 3.8L or 4.0L engine (sales code EGV, EGL or EGQ) - 2009 RT vehicles equipped with a 3.3L or 3.8L or 4.0L engine (sales code EGV, EGL or EGQ built before May 11, 2009 (MDH 0511XX). - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before August 20, 2008 (MDH 0820XX) - 2009 JC vehicles equipped with a 3.5L engine (sales code EGF) built before September 6, 2008 (MDH 0906XX) SYMPTOM/CONDITION: Some customers may complain that the engine stumbles, runs rough, has idle fluctuations and/or surges at idle or there is a MIL illumination. Further investigation by the technician may find DTC: - P0452 - Evap Pressure Switch Stuck Closed DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other then the one listed above are present record them on the repair order and repair as necessary before proceeding Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-003-09C > Jun > 09 > Engine Controls - MIL ON/DTC P0452 Set In Memory > Page 4406 further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer to Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. b. Clear the Variable Line Pressure (VLP) Counters, found in the Misc Function menu for the PCM ECU. VLP Clear Counters must be completed on all models. c. Perform the Quick Learn function, found in the Misc Function menu for the PCM ECU. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 4411 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4417 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4418 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4419 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4420 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4421 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4422 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4423 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4424 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4425 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4426 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 4427 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4434 Pressure Regulating Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4437 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove shift cable (1) from manual lever (2). NOTE: Keep the Top Sound Dampener Cover if replacing the unit 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4438 10. Remove the top valve body oil pan (1) bolts. 11. Remove the solenoid pack connector (2) at valve body oil pan (1). 12. Raise the vehicle on a hoist. 13. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4439 14. Turn the wheel (3) fully to the left. 15. Remove the bolt (2) at the ground cable (3). 16. Remove the clip (1) at the valve body pan. 17. Move cable away from the valve body pan. 18. Remove the pressure tap plug (2) at valve body oil pan. 19. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 20. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4440 21. Remove the bolts (1) at the line pressure sensor. 22. Remove the line pressure sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4441 Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Installation INSTALLATION 1. Install the line pressure sensor on to the valve body. 2. Install the bolts (1) to the line pressure sensor and tighten to 6 Nm (50 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle on a hoist. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4442 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise the vehicle on the hoist. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4443 11. Install the clip to the valve body oil pan 12. Install the Front Sound Damper Cover (2) and install the fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4444 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4445 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4446 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4447 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove the shift cable (1) from the manual lever (2). 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). 10. Remove shift cable (1) from manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4448 11. Remove the top valve body oil pan (1) bolts. 12. Remove the solenoid pack connector (2) at valve body oil pan (1). 13. Raise the vehicle on a hoist. 14. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4449 15. Turn the wheel (3) fully to the left. 16. Remove the bolt (2) at the ground cable (3). 17. Remove the clip (1) at the valve body pan. 18. Move cable away from the valve body pan. 19. Remove the pressure tap plug (2) at valve body oil pan. 20. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 21. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4450 22. Remove the bolt (1) at the pressure control solenoid. 23. Remove the pressure control sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4451 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Installation INSTALLATION 1. Install the pressure control solenoid on to the valve body. 2. Install the bolts (1) to the pressure control solenoid and tighten to 6 Nm (40 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4452 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise and support the vehicle. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4453 11. Install the clip to the valve body oil pan. 12. Install the Front Sound Damper Cover (2) and fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4454 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4455 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4459 Shift Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Removal REMOVAL 1. Remove valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4462 Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4468 Pressure Regulating Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4471 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove shift cable (1) from manual lever (2). NOTE: Keep the Top Sound Dampener Cover if replacing the unit 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4472 10. Remove the top valve body oil pan (1) bolts. 11. Remove the solenoid pack connector (2) at valve body oil pan (1). 12. Raise the vehicle on a hoist. 13. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4473 14. Turn the wheel (3) fully to the left. 15. Remove the bolt (2) at the ground cable (3). 16. Remove the clip (1) at the valve body pan. 17. Move cable away from the valve body pan. 18. Remove the pressure tap plug (2) at valve body oil pan. 19. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 20. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4474 21. Remove the bolts (1) at the line pressure sensor. 22. Remove the line pressure sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4475 Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Installation INSTALLATION 1. Install the line pressure sensor on to the valve body. 2. Install the bolts (1) to the line pressure sensor and tighten to 6 Nm (50 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle on a hoist. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4476 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise the vehicle on the hoist. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4477 11. Install the clip to the valve body oil pan 12. Install the Front Sound Damper Cover (2) and install the fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4478 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4479 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4480 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4481 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove the shift cable (1) from the manual lever (2). 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). 10. Remove shift cable (1) from manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4482 11. Remove the top valve body oil pan (1) bolts. 12. Remove the solenoid pack connector (2) at valve body oil pan (1). 13. Raise the vehicle on a hoist. 14. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4483 15. Turn the wheel (3) fully to the left. 16. Remove the bolt (2) at the ground cable (3). 17. Remove the clip (1) at the valve body pan. 18. Move cable away from the valve body pan. 19. Remove the pressure tap plug (2) at valve body oil pan. 20. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 21. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4484 22. Remove the bolt (1) at the pressure control solenoid. 23. Remove the pressure control sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4485 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Installation INSTALLATION 1. Install the pressure control solenoid on to the valve body. 2. Install the bolts (1) to the pressure control solenoid and tighten to 6 Nm (40 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4486 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise and support the vehicle. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4487 11. Install the clip to the valve body oil pan. 12. Install the Front Sound Damper Cover (2) and fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4488 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor Removal > Page 4489 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4493 Shift Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Removal REMOVAL 1. Remove valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4496 Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Accumulator - Description Accumulator: Description and Operation Accumulator - Description DESCRIPTION The 62TE has six accumulators and are all located in the case under the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Accumulator - Description > Page 4501 Accumulator: Description and Operation Accumulator - Operation OPERATION The function of an accumulator is to cushion the application of a frictional clutch element. When pressurized fluid is applied to a clutch circuit, the application force is dampened by fluid collecting in the respective accumulator chamber against the piston and spring(s). The intended result is a smooth, firm clutch application. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Accumulator - Description > Page 4502 Accumulator: Description and Operation Valve Body - Operation OPERATION REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from the pump, which works against spring tension to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid. In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves. MANUAL VALVE The manual valve is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve is fed to the torque converter regulator valve, where it passes through the valve, and is slightly regulated. The pressure is then directed to the converter clutch switch valve and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. CONVERTER CLUTCH CONTROL VALVE The converter clutch control valve controls the back (on) side of the torque converter clutch. When the PCM/TCM energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under all operating conditions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure Control Module: Service and Repair Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure > Page 4507 Control Module: Service and Repair Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4513 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4518 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 41TE/41AE Estimated Service Fill ....................................................................................................... ........................................................... 4.0 qts (3.8L) 41TE/41AE Overhaul Capacity with Torque Converter Empty ....................................................................................................................... 9.2 qts (8.7L) 62TE Estimated Service Fill ................................................................................................................ ............................................................. 5.5 qts (5.2L) 62TE Overhaul Capacity with Torque Converter Empty ................................................................................................................................. 9.0 qts (8.5L) Dry fill capacity depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4521 Fluid - A/T: Fluid Type Specifications ATF Fluid ..................................................................................................................................................... Mopar ATF +4 Automatic Transmission Fluid Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4522 Fluid - A/T: Description and Operation AUTOMATIC/MANUAL TRANSAXLE FLUID NOTE: All transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Mopar (R) ATF+4 (Automatic Transmission Fluid) is required in the automatic and T355/BG6 manual transaxles. Substitute fluids can induce torque converter clutch shudder, or premature geartrain failure. Mopar (R) ATF+4 (Automatic Transmission Fluid) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check FLUID LEVEL AND CONDITION CHECK FLUID LEVEL CHECK USING THE SCAN TOOL 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. NOTE: When inserting dipstick special tool 9336A, excess insertion force may cause the dipstick to slip past the stop on the bracket in the transmission oil pan. An approximate distance that the dipstick should be inserted into the fill tube is 424 mm (16.69 in.). 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336A into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. 6. Check transmission oil temperature using the appropriate scan tool. 7. The transmission Oil Dipstick 9336A has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the Transmission Fluid Temperature (TFT) as viewed with the scan too, and the Transmission Fluid Graph, determine if the transmission oil level Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 4525 is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. MOPAR(R) ATF+4 (Automatic Transmission Fluid) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 4526 Fluid - A/T: Service and Repair Fluid/Filter Service FLUID AND FILTER SERVICE FLUID/FILTER SERVICE (RECOMMENDED) NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled MOPAR(R) ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Remove nuts at the oil filter. 4. Install a new filter and nuts, tighten to 5 Nm (40 in. lbs.). 5. Install the fluid filter oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 6. Clean the oil pan and magnet. Reinstall pan using new MOPAR(R) Silicone Adhesive sealant. Tighten oil pan bolts to 6 Nm (50 in. lbs.). 7. Pour four Quarts of MOPAR(R) ATF+4 through the dipstick opening. 8. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 in.) below the lowest mark on the dipstick. 10. Recheck the fluid level after the transaxle has reached normal operating temperature 82° C (180°F). Refer to Fluid Level and Condition Check for the proper fluid fill procedure See: Service and Repair/Procedures/Fluid Level and Condition Check. 11. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair FLUID AND FILTER SERVICE FLUID/FILTER SERVICE (RECOMMENDED) NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled MOPAR(R) ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Remove nuts at the oil filter. 4. Install a new filter and nuts, tighten to 5 Nm (40 in. lbs.). 5. Install the fluid filter oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 6. Clean the oil pan and magnet. Reinstall pan using new MOPAR(R) Silicone Adhesive sealant. Tighten oil pan bolts to 6 Nm (50 in. lbs.). 7. Pour four Quarts of MOPAR(R) ATF+4 through the dipstick opening. 8. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 9. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 in.) below the lowest mark on the dipstick. 10. Recheck the fluid level after the transaxle has reached normal operating temperature 82° C (180°F). Refer to Fluid Level and Condition Check for the proper fluid fill procedure See: Service and Repair/Procedures/Fluid Level and Condition Check. 11. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair Fluid Line/Hose: Service and Repair QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove the dust cap by pulling it straight back off of the quick connect fitting (1). 2. Place the properly sized release tool (4) onto the transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide the release tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the release tool 60° to expand the retaining clip. 5. While holding the release tool against the quick connect fitting, pull back on the transmission cooler line to remove it. 6. If the quick connect fitting is damaged or leaking at the transmission oil cooler or transmission, remove the fitting. CONNECT Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4533 1. If removed, install the quick connect fitting into the transmission oil cooler or the transmission. Tighten the fitting to 15 Nm (132 in. lbs.). 2. Align the cooler line (3) with the quick connect fitting while pushing straight into the fitting. 3. Push in on the transmission cooler line until a click is heard or felt. 4. Slide the dust cap (4) down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. The dust cap will only snap over the quick connect fitting when the transmission cooler line is properly installed. NOTE: If the dust cap will not snap into place, repeat step 2. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications OIL PAN Oil Pan Bolts......................................................................................................................................... ....................................................19 Nm (165 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Removal REMOVAL 1. Remove valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4541 Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the center floor console to access the gear selector unit. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Firmly grasp the socket (1) on the side of the gear selector housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the shifter housing. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal > Page 4547 Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the socket (1) on the side of the gear selector housing. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening in the side of the gear selector housing. 4. Insert the bulb and socket into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the center floor console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Locations > Page 4551 Transmission Mode Indicator - A/T: Diagrams Connector - (BODY) 3 WAY LAMP-PRNDL - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4555 Pressure Regulating Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4558 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove shift cable (1) from manual lever (2). NOTE: Keep the Top Sound Dampener Cover if replacing the unit 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4559 10. Remove the top valve body oil pan (1) bolts. 11. Remove the solenoid pack connector (2) at valve body oil pan (1). 12. Raise the vehicle on a hoist. 13. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4560 14. Turn the wheel (3) fully to the left. 15. Remove the bolt (2) at the ground cable (3). 16. Remove the clip (1) at the valve body pan. 17. Move cable away from the valve body pan. 18. Remove the pressure tap plug (2) at valve body oil pan. 19. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 20. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4561 21. Remove the bolts (1) at the line pressure sensor. 22. Remove the line pressure sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4562 Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Installation INSTALLATION 1. Install the line pressure sensor on to the valve body. 2. Install the bolts (1) to the line pressure sensor and tighten to 6 Nm (50 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle on a hoist. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4563 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise the vehicle on the hoist. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4564 11. Install the clip to the valve body oil pan 12. Install the Front Sound Damper Cover (2) and install the fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4565 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4566 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4567 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4568 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove the shift cable (1) from the manual lever (2). 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). 10. Remove shift cable (1) from manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4569 11. Remove the top valve body oil pan (1) bolts. 12. Remove the solenoid pack connector (2) at valve body oil pan (1). 13. Raise the vehicle on a hoist. 14. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4570 15. Turn the wheel (3) fully to the left. 16. Remove the bolt (2) at the ground cable (3). 17. Remove the clip (1) at the valve body pan. 18. Move cable away from the valve body pan. 19. Remove the pressure tap plug (2) at valve body oil pan. 20. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 21. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4571 22. Remove the bolt (1) at the pressure control solenoid. 23. Remove the pressure control sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4572 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Installation INSTALLATION 1. Install the pressure control solenoid on to the valve body. 2. Install the bolts (1) to the pressure control solenoid and tighten to 6 Nm (40 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4573 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise and support the vehicle. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4574 11. Install the clip to the valve body oil pan. 12. Install the Front Sound Damper Cover (2) and fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4575 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 4576 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure Control Module: Service and Repair Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure > Page 4582 Control Module: Service and Repair Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Removal REMOVAL 1. Remove valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4588 Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4592 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4595 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4596 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4597 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4598 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4599 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4604 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4605 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-INPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4608 Transmission Speed Sensor: Diagrams Output Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-OUTPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4609 Transmission Speed Sensor: Diagrams Transfer Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-TRANSFER SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4612 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Operation OPERATION The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4613 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4614 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4615 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Output Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4616 The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4617 NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Transfer Shaft Speed Sensor - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4618 The Transfer Shaft Speed Sensor (3) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Transfer Shaft Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Transfer Shaft Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor Description > Page 4619 The transfer shaft speed sensor (3) is located at the rear of the case (backside). It reads rotation of the front annulus/rear carrier assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4622 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4623 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4624 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4625 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4626 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4627 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Output Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4628 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4629 Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Input Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4630 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4631 Transfer Shaft Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the transfer shaft sensor (3). 2. Remove the bolt at transfer shaft sensor (1). 3. Pull up on transfer shaft sensor to remove. Transfer Shaft Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4632 1. Install a new O-ring (2). on the transfer shaft speed sensor (1). 2. Install transfer shaft speed sensor (3) into case. 3. Install bolt at transfer shaft speed sensor (1) and tighten to 12 Nm (105 in. lbs.). 4. Reconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Description and Operation > Shift Interlock System - Description Shift Interlock: Description and Operation Shift Interlock System - Description DESCRIPTION The Brake Transmission Shifter/Ignition Interlock (BTSI) is a solenoid operated system that prevents the transmission gear shifter from being moved out of PARK without a driver in place. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Description and Operation > Shift Interlock System - Description > Page 4637 Shift Interlock: Description and Operation Shift Interlock System - Operation OPERATION The Brake Transmission Shifter/Ignition Interlock (BTSI) is engaged whenever the ignition switch is in the LOCK or ACC position. An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one-half inch. When the key is in the ON position and the brake pedal is depressed, the shifter is unlocked and will move into any position. When service brake pedal is not depressed the solenoid rotating arm (2) is free to rotate. The shifter gate pin (1) hits the blocking arm (3) and is prevented from moving from park. When service brake is applied the rotating arm (2) is prevented from rotating by magnetic force within the solenoid. The shifter gate pin (1) pushes the rotating arm (2) and blocker arm (3) allowing the shifter to move out of park. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Description and Operation > Page 4638 Shift Interlock: Testing and Inspection SHIFT INTERLOCK SYSTEM The following chart describes the normal operation of the Brake Transmission Shift Interlock (BTSI) system. If the "expected response" differs from the vehicle's response, then system repair is necessary. Refer to the following chart that expected shifter response, depending on ignition key/switch and brake pedal positions. If the shifter cannot be moved out of the PARK position, refer to Shifter Locked In Place below. If the shift lever can be shifted out of PARK without the brake pedal depressed, refer to Circuit Test below. SHIFTER LOCKED IN PLACE 1. Gain access to the brake transmission shift interlock (BTSI) solenoid. The solenoid is part of the shifter assembly. 2. Disconnect the wire connector from the rear of the BTSI solenoid. 3. Insert the ignition key and turn it to the ON position. 4. With the brakes applied, try moving the shifter out of the PARK position. - If the lever now moves freely in and out of PARK, perform the Circuit Test. If the shift lever now moves freely in and out of the park position, the BTSI solenoid is faulty and the shifter must be replaced. If the shift lever still does not move from the park position, the problem is in the shift lever assembly. If the above test pass and the shifter can still be moved freely in and out of PARK without the brake pedal depressed, replace shifter assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4642 Shift Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Removal REMOVAL 1. Remove valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4645 Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Locations Shifter A/T: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Locations > Page 4649 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Shift Lever Assembly C1 (Body) 4 Way Shifter A/T: Diagrams Shift Lever Assembly C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY ASSEMBLY-SHIFTER LEVER - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Shift Lever Assembly C1 (Body) 4 Way > Page 4652 Shifter A/T: Diagrams Shift Lever Assembly C2 (Body) 2 Way Connector C2 - (BODY) 2 WAY ASSEMBLY-SHIFTER LEVER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Shift Lever Assembly C1 (Body) 4 Way > Page 4653 Shifter A/T: Diagrams Shift Lever Assembly C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY ASSEMBLY-SHIFTER LEVER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Shifter - Removal Shifter A/T: Service and Repair Transmission Shifter - Removal REMOVAL 1. Disconnect battery negative cable. 2. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Disconnect harness connector (1). 4. Remove the shift knob by pulling up on the knob. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Shifter - Removal > Page 4656 5. Remove the electrical connectors (1, 2) at the shifter. 6. Disconnect and remove gearshift cable (2, 3) from shift mechanism. 7. Remove four shift mechanism-to-lower console nuts (1). Remove shift mechanism (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Shifter - Removal > Page 4657 Shifter A/T: Service and Repair Transmission Shifter - Installation INSTALLATION 1. Install shifter to studs. 2. Install and tighten the shift mechanism-to-lower console nuts (1) to 8 Nm (71 in. lbs.) . 3. Install gearshift cable (2, 3) to shift mechanism. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Shifter - Removal > Page 4658 4. Connect the harness connectors (1, 2). 5. Install the shifter knob (1). 6. Verify the shifter and transaxle are both in Park. 7. Loosen the cable adjust bolt, then tighten the bolt to 6 Nm (40 in. lb.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Transmission Shifter - Removal > Page 4659 8. Install the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 9. Connect battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Shift Cable - Removal Shift Cable: Service and Repair Shift Cable - Removal REMOVAL 1. Disconnect battery negative cable. 2. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Disconnect and remove gearshift cable (2, 3) from shift mechanism. 4. Remove the air bag module and the dynamics sensor. See: Relays and Modules/Relays and Modules - Restraint Systems/Air Bag Control Module/Service and Repair/Occupant Restraint Controller - Removal. 5. Remove the shift cable at the transmission and pull cable through. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Shift Cable - Removal > Page 4665 Shift Cable: Service and Repair Shift Cable - Installation INSTALLATION 1. Install the shift cable through the bulkhead and ensure that the grommet is seated. 2. Install the cable at the transmission. 3. Install and connect gearshift cable (2, 3) at the shift mechanism. 4. Install the air bag module and the dynamics sensor See: Relays and Modules/Relays and Modules - Restraint Systems/Air Bag Control Module/Service and Repair/Occupant Restraint Controller - Installation. 5. Install the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 6. Connect the battery. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Torque Converter - Description Torque Converter: Description and Operation Torque Converter - Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (4), an over-running clutch, an impeller (2) and an electronically applied converter clutch (5). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub (3) drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. IMPELLER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Torque Converter - Description > Page 4670 The impeller (3) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine (4,5), so is the impeller, because they are one and the same and are the driving member of the system. TURBINE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Torque Converter - Description > Page 4671 The turbine (1) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft (3) is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR The stator assembly (1) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller (2) and turbine (4) within the torque converter case. The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Torque Converter - Description > Page 4672 The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller (3) and turbine (5) were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) was added to the turbine (5), and a friction material (7) was added to the inside of the front cover (1) to provide this mechanical lock-up. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Torque Converter - Description > Page 4673 Torque Converter: Description and Operation Torque Converter - Operation OPERATION The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades, it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Torque Converter - Description > Page 4674 before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston to the front cover's friction material, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Control Module (PCM). The engagement cannot be activated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle speed and throttle position. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch will engage at approximately 56 km/h (35 mph) with light throttle, after the shift to third gear. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Torque Converter - Removal Torque Converter: Service and Repair Torque Converter - Removal REMOVAL 1. Remove transmission and torque converter from vehicle See: Service and Repair/Removal and Replacement/Removal. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Torque Converter - Removal > Page 4677 Torque Converter: Service and Repair Torque Converter - Installation INSTALLATION NOTE: Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be 1/2 in. to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle See: Service and Repair/Removal and Replacement/Installation. 9. Fill the transmission with the recommended fluid, See: Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Description Transmission Cooler: Description and Operation Description DESCRIPTION An external oil-to-air type automatic transmission oil cooler is mounted to the front of the radiator and is integral to the A/C condenser. The six upper tubes are used for transaxle oil cooling, and the remaining tubes below are for the A/C system. The cooler uses tubes and rubber hoses to feed oil to and from the automatic transaxle. The replaceable inlet and outlet tubes use quick-connect type fittings. The trans oil cooler is replaced with the A/C condenser. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Description > Page 4682 Transmission Cooler: Description and Operation Operation OPERATION The oil flows from the transmission to the oil-to-air cooler. Heat is then transferred into the air. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures Cleaning CLEANING Check the AC condenser for debris on the cooling fin surfaces. Clean as necessary. Inspection INSPECTION Inspect all hoses, tubes, clamps and connections for leaks, cracks, or damage. Replace as necessary. Use only approved transmission oil cooler hoses that are molded to fit the space available. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4685 Transmission Cooler: Removal and Replacement Removal TRANSMISSION OIL COOLER 1. The transmission oil cooler is integral to the A/C condenser. To remove the AC condenser assembly, See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/A/C Condenser - Removal. Installation TRANSMISSION OIL COOLER 1. The transmission oil cooler is integral to the A/C condenser. To install the AC condenser assemblySee: Heating and Air Conditioning/Condenser HVAC/Service and Repair/A/C Condenser - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Locations > Page 4689 Transmission Mode Indicator - A/T: Diagrams Connector - (BODY) 3 WAY LAMP-PRNDL - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4693 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4696 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4697 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4698 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4699 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4700 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4705 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4706 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-INPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4709 Transmission Speed Sensor: Diagrams Output Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-OUTPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4710 Transmission Speed Sensor: Diagrams Transfer Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-TRANSFER SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4713 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Operation OPERATION The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4714 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4715 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4716 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Output Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4717 The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4718 NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Transfer Shaft Speed Sensor - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4719 The Transfer Shaft Speed Sensor (3) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Transfer Shaft Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Transfer Shaft Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4720 The transfer shaft speed sensor (3) is located at the rear of the case (backside). It reads rotation of the front annulus/rear carrier assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4723 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4724 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4725 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4726 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4727 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4728 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Output Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4729 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4730 Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Input Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4731 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4732 Transfer Shaft Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the transfer shaft sensor (3). 2. Remove the bolt at transfer shaft sensor (1). 3. Pull up on transfer shaft sensor to remove. Transfer Shaft Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4733 1. Install a new O-ring (2). on the transfer shaft speed sensor (1). 2. Install transfer shaft speed sensor (3) into case. 3. Install bolt at transfer shaft speed sensor (1) and tighten to 12 Nm (105 in. lbs.). 4. Reconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation Valve Body: Description and Operation OPERATION REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from the pump, which works against spring tension to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid. In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves. MANUAL VALVE The manual valve is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve is fed to the torque converter regulator valve, where it passes through the valve, and is slightly regulated. The pressure is then directed to the converter clutch switch valve and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. CONVERTER CLUTCH CONTROL VALVE The converter clutch control valve controls the back (on) side of the torque converter clutch. When the PCM/TCM energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under all operating conditions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement Valve Body: Removal and Replacement Valve Body - Removal REMOVAL 1. Remove the engine cover. 2. Remove the negative battery. 3. Drain the radiatorSee: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Remove clamps at the lower radiator hose. 5. Remove the lower radiator hose. 6. Remove shift cable (1) from manual lever (2). 7. Remove the fasteners (1) and the Front Sound Damper Cover (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4739 8. Remove the top valve body oil pan (1) bolts. 9. Remove the solenoid pack connector (2) at valve body oil pan (1). 10. Raise the vehicle on a hoist. 11. Remove the front left side inner wheel splash screws from front side of wheel opening. 12. Turn the wheel fully to the left. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4740 13. Remove the pressure tap plug (2) at valve body oil pan. 14. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 15. Remove the valve body oil pan. 16. Remove the electrical connector (1) at the valve body (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4741 17. Remove screw at detente arm (2). 18. Remove detente arm (1). 19. Remove the twenty one valve body to case bolts (1). 20. Insure the manual lever is fully forward to keep the manual valve pin (3) from binding. 21. Pull the valve body away from the underdrive compounder assembly oil transfer tubes (2) and lift up on valve body to clear the manual valve pin past the slot in the rooster comb. Valve Body - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4742 1. Raise the vehicle on the hoist. 2. Install a NEW 2/4 clutch oil seal (1). 3. Install new O-rings (1) on the underdrive compounder assembly oil transfer tubes (2). 4. Insure the manual lever is fully forward to keep the manual valve pin (3) from binding. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4743 5. Set the manual valve pin (3) into the slot in the rooster comb. 6. Set the valve body into the underdrive compounder assembly oil transfer tubes (2) and press the valve body into place. 7. Install the twenty one valve body to case bolts and tighten to 6 Nm (50 in. lbs.). 8. Install the detente arm (1) onto the pin at the valve body. 9. Install the screw (3) at the detente arm and tighten to 6 Nm (50 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4744 10. Install the electrical connector (1) at the valve body. 11. Lower the hoist. 12. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 13. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 14. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 15. Lower the vehicle on a hoist. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4745 16. Install the solenoid pack connector (2) at valve body oil pan. 17. Raise the vehicle on the hoist. 18. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 19. Install the left side inner wheel splash shield screws (1). 20. Install the Front Sound Damper Cover (2) and the fasteners (1). 21. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4746 22. Install shift cable (1) to manual lever (2). 23. Install lower radiator hose and clamps. 24. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 25. Install the battery cable. 26. Fill transmission and road test See: Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4747 Valve Body: Overhaul Valve Body - Disassembly DISASSEMBLY 1. Unplug the electrical connectors (1, 2) at the valve body. 2. Remove the bolts (1) at the transfer plate (2) and remove the transfer plate. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4748 3. Turn valve body over and remove the solenoid module (1) from the valve body (2). 4. Remove the bolts (1) at the line pressure sensor (2). 5. Remove the line pressure sensor from the valve body. 6. Remove the bolt (1) at the pressure control solenoid (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4749 7. Remove the bolts (1) at the clamping plate (2). 8. Remove the clamping plate (1). 9. Remove the valve body cover (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4750 10. Remove the valve body inner gasket and plate (1) from the valve body. . NOTE: The valve body contains some check balls that are pressed into a tapered bore (1). These check balls are not removeable 11. Remove the check balls (2) if equipped. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4751 NOTE: Use exploded view for disassembly. NOTE: Tag all valve/spring assemblies for reassembly identification. 12. Remove valves from valve body. Valve Body - Assembly ASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4752 NOTE: Use exploded view for assembly. 1. Install the valves into valve body. NOTE: The valve body contains some check balls that are pressed into a tapered bore (1). These check balls are not removeable 2. Install the check balls (2) if equipped. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4753 3. Install the inner separator plate (1). 4. Install the outer separator plate (1). 5. Install the transfer plate (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4754 6. Install the bolts (1) at the transfer plate (2) and tighten to 6 Nm (50 in. lbs.). 7. Install the pressure control solenoid on to the valve body. 8. Install the bolt (1) at the pressure control solenoid (2) and tighten to 6 Nm (50 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4755 9. Install the pressure control sensor onto the valve body. 10. Install the bolts (1) to the pressure control sensor and tighten to 6 Nm (50 in. lbs.). 11. Install the solenoid pack (1) onto the valve body (2). 12. Turn valve body over and install the clamp plate (2) onto the valve body. 13. Install the clamp plate bolts and tighten to 6 Nm (50 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4756 14. Plug in the electrical connectors pressure control solenoid and pressure control sensors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4763 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4770 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4775 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4781 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Page 4782 Fluid - Differential: Specifications Rear Drive Assembly (RDA) .......................................................................................................................... Mopar Gear Lubricant 75W-90 or equivalent Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Page 4783 Fluid - Differential: Service and Repair STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID CHANGE The drain plug (2) for the differential assembly is located in the bottom of the differential assembly case, toward the rear of the unit. The fill plug (3) for the differential assembly is located on the left side of the assembly case. The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. 1. Raise the vehicle on a hoist. 2. Position a drain pan under the differential drain plug. 3. Remove the drain plug and allow the fluid to drain into the pan. 4. Install the drain plug and torque to 35 Nm (26 ft. lbs.). 5. Re-position the drain pan under the differential fill plug. 6. Remove the differential fill plug. 7. Using a suction gun or equivalent, fill the differential assembly with 0.7 L (0.74 Quarts) of Mopar(R) Gear and Axle Lubricant (75W-90). 8. Install the fill plug and torque to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Output Seal - Removal Seals and Gaskets: Service and Repair Output Seal - Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove rear driveline module.See: Service and Repair/Removal and Replacement/Rear Driveline Module/Removal 3. Use suitable screwdriver (2) to remove output seal (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Output Seal - Removal > Page 4788 Seals and Gaskets: Service and Repair Output Seal - Installation INSTALLATION 1. Install output flange seal to differential housing using handle C- 4171A (1) and installer 8493 (2). 2. Install rear driveline module. See: Service and Repair/Removal and Replacement/Rear Driveline Module/Installation 3. Check differential assembly fluid level and adjust as required. See: Service and Repair/Procedures Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Outer Boot - Removal Constant Velocity Joint Boot: Service and Repair Front Half Shaft, Outer Boot - Removal REMOVAL 1. Remove halfshaft assembly requiring boot replacement from vehicle. See: Service and Repair/Half Shaft - Removal 2. Remove large boot clamp (4) retaining CV joint sealing boot to CV joint housing (3) and discard. Remove small clamp (1) that retains outer CV joint sealing boot to interconnecting shaft (5) and discard. Remove sealing boot (2) from outer CV joint housing and slide it down interconnecting shaft. 3. Wipe away grease to expose outer CV joint and interconnecting shaft. 4. Remove outer CV joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer (1), sharply hit the end of the CV joint housing to dislodge housing from internal circlip (3) on interconnecting shaft. Then slide outer CV joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Outer Boot - Removal > Page 4795 NOTE: Always use a new circlip. 5. Remove large circlip (3) from the interconnecting shaft (2) before attempting to remove outer CV joint sealing boot. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Outer Boot - Removal > Page 4796 Constant Velocity Joint Boot: Service and Repair Front Half Shaft, Outer Boot - Installation INSTALLATION 1. Slide new sealing boot clamp (2) onto interconnecting shaft (4). Slide the outer CV joint assembly sealing boot (1) onto the interconnecting shaft (4). Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. NOTE: Always use a new circlip. 2. Align splines on interconnecting shaft with splines on cross of outer CV joint assembly and start outer CV joint onto interconnecting shaft. 3. Install outer CV joint assembly onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (2) (with hub nut (4) installed) until outer CV joint (3) is fully seated on interconnecting shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Outer Boot - Removal > Page 4797 4. Outer CV joint assembly must be installed on interconnecting shaft until cross (2) of outer CV joint assembly (3) is seated against circlip on interconnecting shaft (1). 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot (4). 6. Install outer CV joint sealing boot to interconnecting shaft clamp evenly on sealing boot. 7. Clamp sealing boot onto interconnecting shaft (2) using crimper, Crimping Tool C-4975A and the following procedure. Place Crimping Tool C-4975A (1) over bridge of clamp (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Outer Boot - Removal > Page 4798 8. Tighten nut on Crimping Tool C-4975A until jaws on tool (2) are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 9. Position outer CV joint sealing boot (4) into its retaining groove on outer CV joint housing. Install sealing boot to outer CV joint retaining clamp (1) evenly on sealing boot. 10. Clamp sealing boot onto outer CV joint housing using Crimping Tool C-4975A (3) and the following procedure. Place Crimping Tool C-4975A over bridge of clamp (1). 11. Tighten nut on Crimping Tool C-4975A until jaws on tool are closed completely together (4), face to face. 12. Install the halfshaft requiring boot replacement back on the vehicle. See: Service and Repair/Half Shaft - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel bearing grease ............................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The front wheel bearing and wheel hub of this vehicle are a one piece sealed unit or hub and bearing unit type assembly. The hub and bearing (1) is mounted to the knuckle using four mounting bolts (2) and to the axle half shaft using a retaining nut. The center of the hub and bearing is splined to match the outer joint of the axle half shaft. Each front hub and bearing has five wheel mounting studs on the hub flange for mounting the wheel to the vehicle. The wheel mounting studs are the only replaceable components of the hub and bearing. Otherwise, the hub and bearing is serviced as a complete assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 4804 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (1) is mounted to the rear knuckle. All vehicles have a magnetic encoder integrated into the rear hub and bearing for speed sense. The encoder works with the rear wheel speed sensor (2) to provide wheel speed signal. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the hub and bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 4807 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Steering and Suspension/Suspension/Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4810 5. Remove the four bolts (2) fastening the hub and bearing to the knuckle (3). 6. Slide the hub and bearing (1) off the half shaft and out of the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4811 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the hub and bearing (1) by sliding it over the half shaft and into the knuckle. 2. Install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 Nm (60 ft. lbs.). 3. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 4. Clean all foreign matter from the threads of the half shaft outer C/V joint. 5. Install the hub nut (1) on the end of the half shaft (2) and lightly tighten it. 6. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (1) to 132 Nm (97 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4812 7. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4813 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal ALL-WHEEL-DRIVE NOTE: Before proceeding, See: Steering and Suspension/Suspension/Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. This will also allow more room to access the hub and bearing mounting bolts in a later step. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4814 6. Remove two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle (3). 7. Remove the disc brake caliper and adapter bracket (2) as an assembly from the knuckle (3) and rotor. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 8. Remove any retaining clips, then slide the brake rotor (2) off the hub and bearing (1). CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 9. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 10. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4815 11. Remove the four bolts (1) securing the hub and bearing to the knuckle. 12. Remove the hub and bearing from the knuckle and half shaft (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4816 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation ALL-WHEEL-DRIVE 1. With the brake shield in place on the knuckle, slide the hub and bearing over the axle half shaft and position it on the knuckle. 2. Install the four bolts (1) securing the hub and bearing to the knuckle. Tighten the bolts to 105 Nm (77 ft. lbs.). CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 3. Pass the wheel speed sensor head (2) through the hole in the brake shield, then push it into the mounting hole in hub and bearing (1) and align the mounting screw hole. 4. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4817 5. Clean the rotor mounting face of the hub and bearing (1) to remove any dirt or corrosion. 6. Install the brake rotor (2) over the hub and bearing (1). CAUTION: If the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism. 7. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4818 8. Install the disc brake caliper and adapter bracket (2) over the knuckle and rotor as an assembly. 9. Install the two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle. Tighten the mounting bolts to 100 Nm (74 ft. lbs.). NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 10. Clean all foreign matter from the threads of the half shaft outer C/V joint. 11. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 12. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 13. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 14. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 4819 15. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Check the brake fluid level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension Hub Nut................................................................................................................................................ .....................................................132 Nm (97 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 4825 Axle Nut: Specifications Rear Suspension Hub Nut................................................................................................................................................ ...................................................245 Nm (181 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft - Description Drive/Propeller Shaft: Description and Operation Propeller Shaft - Description DESCRIPTION WARNING: Due to propeller shaft imbalance concerns, the propeller shaft can only be serviced as an assembly. AWD models utilize a "three-piece" propeller shaft to transmit torque to the rear driveline module assembly. This three-piece design consists of: - Front center and rear shaft segments - Plunging front CV joint. - Center support bearings - Rubber coupler at driveline module flange The front shaft segment utilizes a plunging CV joint at the power transfer unit connection. The center and rear shaft segments utilize a support bearing/bracket assembly. The rear shaft segment uses a rubber coupler at the driveline module flange. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft - Description > Page 4831 Drive/Propeller Shaft: Description and Operation Propeller Shaft - Operation OPERATION The propeller shaft is used to transmit torque from the transaxle power transfer unit (PTU) to the rear driveline module of AWD equipped models. The propeller shaft front segment utilizes a plunging CV joint at the PTU flange. The joint is flexible, allowing for torsional movement of the powertrain. The propeller shaft center and rear segments utilize a support bearing/bracket, which support this three-piece assembly and isolates driveline vibrations from the body. The rubber coupler at the driveline module flange dampens out propeller shaft torsional vibrations, as the driveline module it connects to is fastened to the rear suspension crossmember. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Removal Drive/Propeller Shaft: Service and Repair Propeller Shaft - Removal REMOVAL 1. Raise the vehicle on the hoist. 2. Mark propeller shaft and differential for proper installation. 3. Remove rear propeller shaft to rear axle retaining nuts (1). 4. Remove the bolts (3) from the center support heat shield (2). CAUTION: Propeller shaft removal. Never allow propeller shaft to hang while connected to Power Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft section is hung unsupported, damage may occur to joint, boot and/or center bearing from over-angulation. This may result in vibration/balance issues. A helper may be needed. 5. Remove the heat shield (2). 6. Remove the center support mounting bolts (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Removal > Page 4834 7. Remove the bolts (2) at the PTU 8. Remove the propeller shaft (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Removal > Page 4835 Drive/Propeller Shaft: Service and Repair Propeller Shaft - Installation INSTALLATION CAUTION: Propeller shaft installation. Never allow propeller shaft to hang while connected to Power Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft section is hung unsupported, damage may occur to joint, boot and/or center bearing from over-angulation. This may result in vibration/balance issues. A helper may be needed. 1. Make sure transaxle is in Neutral (N) position. 2. Obtain a helper if needed and lift propeller shaft assembly into position. Install propeller shaft to PTU with mounting bolts and tighten to 30 Nm (22 ft. lbs.). 3. Align marks (2) on propeller shaft with marks on rear axle flange. Install propeller shaft and bolts, tighten the bolts to 58 Nm (43 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft - Removal > Page 4836 4. Raise the center support into position and install mounting bolts (1), tighten bolts to 41 Nm (30 lbs.ft.). 5. Install heat shield (2) and retaining nuts tighten to 21 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications FLEX PLATE Flex plate to Crankshaft........................................................................................................................ ........................................................95 Nm (70 ft.lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Flexplate - Removal Flex Plate: Service and Repair Flexplate - Removal REMOVAL 1. Remove the transaxle. See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal 2. Remove 8 flex plate attaching bolts (2). 3. Remove backing plate (3) 4. Remove the flex plate (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Flexplate - Removal > Page 4842 Flex Plate: Service and Repair Flexplate - Installation INSTALLATION 1. Position the flex plate (1) with backing plate (3) on the crankshaft. 2. Apply Mopar(R) Lock & Seal Adhesive to the eight flex plate bolts (2). 3. Install the flex plate bolts (2). Tighten the bolts to 95 Nm (70 ft. lbs.). 4. Install the transaxle See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Installation NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the center floor console to access the gear selector unit. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Firmly grasp the socket (1) on the side of the gear selector housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the shifter housing. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal > Page 4849 Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the socket (1) on the side of the gear selector housing. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening in the side of the gear selector housing. 4. Insert the bulb and socket into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the center floor console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Locations > Page 4853 Transmission Mode Indicator - A/T: Diagrams Connector - (BODY) 3 WAY LAMP-PRNDL - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4860 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4865 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure Control Module: Service and Repair Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure > Page 4872 Control Module: Service and Repair Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4877 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4880 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the all-wheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4881 provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction control. It only works on situations where front-to-rear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Remove the left front trim panel. 2. Remove the electrical connector. 3. Remove the mounting nuts. 4. Remove the ECC module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 4884 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Install ECC module into mounting studs. 2. Install mounting nuts and tighten to 8 Nm (71 in. lbs.) torque. 3. Install the electrical connector. 4. Install the left front trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Removal REMOVAL 1. Remove valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 4891 Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4895 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4898 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4899 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4900 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4901 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4902 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4907 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4908 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-INPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4911 Transmission Speed Sensor: Diagrams Output Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-OUTPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 4912 Transmission Speed Sensor: Diagrams Transfer Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-TRANSFER SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4915 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Operation OPERATION The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4916 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4917 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4918 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Output Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4919 The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4920 NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Transfer Shaft Speed Sensor - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4921 The Transfer Shaft Speed Sensor (3) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Transfer Shaft Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Transfer Shaft Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 4922 The transfer shaft speed sensor (3) is located at the rear of the case (backside). It reads rotation of the front annulus/rear carrier assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4925 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4926 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4927 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4928 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4929 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4930 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Output Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4931 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4932 Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Input Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4933 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4934 Transfer Shaft Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the transfer shaft sensor (3). 2. Remove the bolt at transfer shaft sensor (1). 3. Pull up on transfer shaft sensor to remove. Transfer Shaft Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 4935 1. Install a new O-ring (2). on the transfer shaft speed sensor (1). 2. Install transfer shaft speed sensor (3) into case. 3. Install bolt at transfer shaft speed sensor (1) and tighten to 12 Nm (105 in. lbs.). 4. Reconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4940 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4943 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the all-wheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4944 provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction control. It only works on situations where front-to-rear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Remove the left front trim panel. 2. Remove the electrical connector. 3. Remove the mounting nuts. 4. Remove the ECC module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 4947 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Install ECC module into mounting studs. 2. Install mounting nuts and tighten to 8 Nm (71 in. lbs.) torque. 3. Install the electrical connector. 4. Install the left front trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4953 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4958 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 4959 Fluid - Transfer Case: Specifications Power Transfer Unit (PTU) ............................................................................................................................ Mopar Gear Lubricant 75W-90 or equivalent Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 4960 Fluid - Transfer Case: Service and Repair PTU FLUID DRAIN/FILL 1. Raise vehicle on hoist. 2. Remove bolt (1) from lower part of PTU heat shield (2). 3. Using a long prybar remove the retaining clip (1) from the side of the PTU heat shield (2). NOTE: Position the PTU heat shield aside as necessary 4. Remove PTU drain plug (1). Drain fluid into suitable container. 5. Install drain plug (1) and torque to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 4961 6. A 10mm hex bit 7/8" long (1) and a ratcheting box angle wrench (2) will be required to remove the PTU fill plug. NOTE: Position the PTU heat shield aside as necessary 7. Using the ratcheting box angle wrench (1) and hex bit (3) remove the PTU fill plug (2). 8. Use a gear lube pump (1) to fill PTU with.8L (1.7 Pints.) of Mopar(R) 75W-90 Gear and Axle Lubricant. 9. Install fill plug and torque to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Page 4962 10. Reposition the PTU heat shield (2) to the side of the PTU, and install a new retaining clip (1). 11. Reposition the PTU heat shield (2) to the bottom of the PTU, and install bolt (1). Tighten to 12 Nm (105 in. lbs.). 12. Lower vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4967 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4970 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the all-wheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4971 provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction control. It only works on situations where front-to-rear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Remove the left front trim panel. 2. Remove the electrical connector. 3. Remove the mounting nuts. 4. Remove the ECC module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 4974 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Install ECC module into mounting studs. 2. Install mounting nuts and tighten to 8 Nm (71 in. lbs.) torque. 3. Install the electrical connector. 4. Install the left front trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal Seals and Gaskets: Service and Repair Inner Axle Drive Shaft Seal - Removal REMOVAL 1. Remove Power Transfer Unit. See: Service and Repair/Removal and Replacement/Power Transfer Unit - Removal 2. Remove outer halfshaft seal (2). 3. Remove power transfer unit end cover (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4979 4. Using suitable screwdriver or punch, remove inner halfshaft seal (1) and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4980 Seals and Gaskets: Service and Repair Inner Axle Drive Shaft Seal - Installation INSTALLATION 1. Using Driver Handle C-4171 (2) and Installer 9683 (1), install inner halfshaft seal until it bottoms in bore. 2. Install roller bearing. 3. Install end cover (1) to PTU housing. Install and torque end cover-to-housing bolts (2) to 28 Nm (20 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4981 4. Using driver Handle C-4171 (1) and seal Installer 6536-A (2), install outer halfshaft seal (3). 5. Install PTU assembly. See: Service and Repair/Removal and Replacement/Power Transfer Unit Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4982 Seals and Gaskets: Service and Repair Inner Axle Drive Shaft Seal - Removal REMOVAL 1. Remove Power Transfer Unit. See: Service and Repair/Removal and Replacement/Power Transfer Unit - Removal 2. Remove outer halfshaft seal (2). 3. Remove power transfer unit end cover (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4983 4. Using suitable screwdriver or punch, remove inner halfshaft seal (1) and discard. Inner Axle Drive Shaft Seal - Installation INSTALLATION 1. Using Driver Handle C-4171 (2) and Installer 9683 (1), install inner halfshaft seal until it bottoms in bore. 2. Install roller bearing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4984 3. Install end cover (1) to PTU housing. Install and torque end cover-to-housing bolts (2) to 28 Nm (20 ft. lbs.). 4. Using driver Handle C-4171 (1) and seal Installer 6536-A (2), install outer halfshaft seal (3). 5. Install PTU assembly. See: Service and Repair/Removal and Replacement/Power Transfer Unit Installation Outer Axle Drive Shaft Seal - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4985 1. Remove right halfshaft assembly. See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Removal 2. Using suitable screwdriver (1), remove outer halfshaft seal (2). Outer Axle Drive Shaft Seal - Installation INSTALLATION 1. Install outer halfshaft seal using Handle C-4171 and Installer 6536-A. 2. Install right halfshaft assembly. See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Installation Differential Carrier Seal - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4986 NOTE: The Power Transfer Unit must be removed from the vehicle to replace this O-ring. 1. Remove PTU from transaxle. See: Service and Repair/Removal and Replacement/Power Transfer Unit - Removal 2. Remove the O-ring. Differential Carrier Seal - Installation INSTALLATION 1. Install a new O-ring (1). 2. Install the PTU to the transaxle. See: Service and Repair/Removal and Replacement/Power Transfer Unit - Installation. 3. Check PTU fluid level See: Fluid - Transfer Case/Service and Repair. Input Shaft Seal - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4987 1. Remove power transfer unit. See: Service and Repair/Removal and Replacement/Power Transfer Unit - Removal 2. Using drill and suitable bit (2), drill hole in input shaft seal (1) to facilitate removal with slide hammer. Use care not to damage the shaft sealing surface. 3. Using slide hammer and suitable screw, remove input shaft seal. Input Shaft Seal - Installation INSTALLATION 1. Using Handle C4171 (1) and Installer L-4429-3 (2), install input shaft seal. 2. Install Power Transfer Unit. See: Service and Repair/Removal and Replacement/Power Transfer Unit Installation Output Flange Seal - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4988 1. Remove propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Propeller Shaft - Removal. 2. Using Spanner Wrench 6958 (1) and suitable ratchet and socket, remove output flange nut 3. Install Puller 1026 (1) and remove PTU output flange (2). 4. Using suitable screwdriver, remove seal and discard. Output Flange Seal - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4989 1. Using Installer 9684 (1) and Handle C-4171(2), install new PTU output flange seal. 2. Using Installer 9321 (2) and Handle C-4171 ,(1) install output flange (3). Lightly tap on flange until sufficient threads are exposed to start flange nut by hand. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Inner Axle Drive Shaft Seal - Removal > Page 4990 3. Using Spanner Wrench 6958 (1), install and torque output flange nut to 102 Nm (75 ft. lbs.) torque. 4. Install propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Propeller Shaft - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4997 Pressure Regulating Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5000 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove shift cable (1) from manual lever (2). NOTE: Keep the Top Sound Dampener Cover if replacing the unit 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5001 10. Remove the top valve body oil pan (1) bolts. 11. Remove the solenoid pack connector (2) at valve body oil pan (1). 12. Raise the vehicle on a hoist. 13. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5002 14. Turn the wheel (3) fully to the left. 15. Remove the bolt (2) at the ground cable (3). 16. Remove the clip (1) at the valve body pan. 17. Move cable away from the valve body pan. 18. Remove the pressure tap plug (2) at valve body oil pan. 19. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 20. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5003 21. Remove the bolts (1) at the line pressure sensor. 22. Remove the line pressure sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5004 Pressure Regulating Solenoid: Service and Repair Pressure Control Sensor - Installation INSTALLATION 1. Install the line pressure sensor on to the valve body. 2. Install the bolts (1) to the line pressure sensor and tighten to 6 Nm (50 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle on a hoist. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5005 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise the vehicle on the hoist. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5006 11. Install the clip to the valve body oil pan 12. Install the Front Sound Damper Cover (2) and install the fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5007 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5008 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5009 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Removal REMOVAL 1. Remove the engine cover. 2. Remove the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the relay (1) at the core support. 4. Drain the radiator See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove clamps (1) at the upper radiator hose (2). 6. Remove the upper radiator hose See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5010 7. Remove the bolts (1) holding the power steering lines (2). 8. Remove the shift cable (1) from the manual lever (2). 9. Remove the fasteners (1) and the Front Sound Damper Cover (2). 10. Remove shift cable (1) from manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5011 11. Remove the top valve body oil pan (1) bolts. 12. Remove the solenoid pack connector (2) at valve body oil pan (1). 13. Raise the vehicle on a hoist. 14. Remove the front left side inner wheel splash screws from front side of wheel opening (1) and fold shield (2) back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5012 15. Turn the wheel (3) fully to the left. 16. Remove the bolt (2) at the ground cable (3). 17. Remove the clip (1) at the valve body pan. 18. Move cable away from the valve body pan. 19. Remove the pressure tap plug (2) at valve body oil pan. 20. Remove the lower valve body oil pan bolts (1) and drain transmission fluid. 21. Remove the valve body oil pan. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5013 22. Remove the bolt (1) at the pressure control solenoid. 23. Remove the pressure control sensor from the valve body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5014 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid - Installation INSTALLATION 1. Install the pressure control solenoid on to the valve body. 2. Install the bolts (1) to the pressure control solenoid and tighten to 6 Nm (40 in. lbs.). 3. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41). 4. Install the upper valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 5. Install the pressure tap at valve body oil pan and tighten to 6 Nm (50 in. lbs.). 6. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5015 7. Install the solenoid pack connector (2) at valve body oil pan. 8. Raise and support the vehicle. 9. Install the lower valve body oil pan bolts and tighten to 6 Nm (50 in. lbs.). 10. Install the bolt at the ground cable and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5016 11. Install the clip to the valve body oil pan. 12. Install the Front Sound Damper Cover (2) and fasteners (1). 13. Move left side inner wheel splash shield (2) into place. 14. Install the left side inner wheel splash shield screws (1). 15. Lower the vehicle. 16. Install the bolts (1) holding the power steering lines (2) and tighten to 10 Nm (90 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5017 17. Install shift cable (1) to manual lever (2). 18. Install upper radiator hose (2) and clamps (1). 19. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Pressure Control Sensor - Removal > Page 5018 20. Install the relay (1) at the core support. 21. Install the battery and battery tray See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 22. Install the battery cables. 23. Fill transmission and road test See: Automatic Transmission/Transaxle/Service and Repair/Procedures/Fluid/Filter Service. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5022 Shift Solenoid: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Removal REMOVAL 1. Remove valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 5025 Shift Solenoid: Service and Repair Transmission Solenoid and Pressure Switch Assembly Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the center floor console to access the gear selector unit. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Firmly grasp the socket (1) on the side of the gear selector housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the shifter housing. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal > Page 5032 Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the socket (1) on the side of the gear selector housing. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening in the side of the gear selector housing. 4. Insert the bulb and socket into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the center floor console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Locations > Page 5036 Transmission Mode Indicator - A/T: Diagrams Connector - (BODY) 3 WAY LAMP-PRNDL - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure Control Module: Service and Repair Quick Learn Procedure QUICK LEARN PROCEDURE The quick learn procedure requires the use of the scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: - Transaxle Assembly Replacement - Powertrain Control Module Replacement - Solenoid/Pressure Switch Assembly Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15.5° C (60° F) and below 93° C (200° F) 1. Plug the scan tool into the diagnostic connector. The connector is located under the instrument panel. 2. Go to the Transmission screen. 3. Go to the Miscellaneous screen. 4. Select Quick Learn Procedure. Follow the instructions of the scan tool to perform the Quick Learn Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Quick Learn Procedure > Page 5043 Control Module: Service and Repair Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5048 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION The AWD ECM (electronic control module) mounts on the driver side cowl side panel, where it is concealed by the instrument panel. It communicates with other systems over the high-speed CAN-C bus. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5051 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is passive and power is transmitted to the front wheels alone. The system functions to optimize traction and handling under the following conditions: Anticipates slip by responding to pedal position unlike all-wheel drive systems that rely on pumps or viscous fluids to transfer torque, the system requires no front-to-rear slippage for activation. This allows the system to transfer torque in response to accelerator pedal position. If the driver is asking for a lot of power, the system immediately starts clamping the Electronically Controlled Coupling (ECC), transferring a high percentage of power to the rear wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four tires. This mode of operation is called open-loop operation in that there is no feedback to affect the torque transfer. Modulates torque to optimize traction on slippery surfaces a second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine the appropriate torque transfer. When the front wheels slip, the all-wheel-drive electronic control module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same aggressive launch described above with the front wheels on ice and the rear wheels on dry pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch the vehicle. Both modes are always active and the maximum of the two is chosen. Power to the rear wheels is modulated during lost of traction while traveling at freeway speeds; for example, hydroplaning on a puddle of water, will send very little power to the rear wheels because the controller knows at those speeds a lot of power is not needed at the rear wheels. Prevents binding during low-speed turns a third condition, which is independent of the others, uses the ESP steering angle sensor to determine when the vehicle is turning in a tight circle. This condition causes the electronic control module to reduce torque to the rear wheels to prevent binding in the driveline. The electronic control module is always checking for this condition as well. Influences handling at moderate speeds. The AWD system is used to influence vehicle dynamics. Other manufacturers limit AWD to aiding traction or providing off-road capability. They concentrate on launching the vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they use it to limit wheel slip for traction. Additional ECM calibration controls torque to the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range, the system utilizes torque to the rear wheels during cornering with the throttle open to make the car turn more easily - make the handling more neutral. This is more readily accomplished with an electronically controlled system, than with viscous-coupling or gerotor systems that require some degree of front-to-rear slip to transfer torque to the rear wheels. Above 53 mph (113 km/hr), the control strategy Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5052 provides minimal torque to the rear wheels under normal driving conditions to aid fuel economy. Works with ESP and Traction Control the electronic control module also interfaces with the ESP and traction control systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle. For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. The AWD system is not traction control. It only works on situations where front-to-rear traction varies, for instance, front wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid side-to-side traction. ESP does that through brake intervention. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Remove the left front trim panel. 2. Remove the electrical connector. 3. Remove the mounting nuts. 4. Remove the ECC module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 5055 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Install ECC module into mounting studs. 2. Install mounting nuts and tighten to 8 Nm (71 in. lbs.) torque. 3. Install the electrical connector. 4. Install the left front trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Removal REMOVAL 1. Remove valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Remove the clamp plate bolts and clamp plate. 3. Remove the electrical connectors to the pressure control solenoid and line pressure sensors. 4. Remove the solenoid/pressure switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Transmission Solenoid and Pressure Switch Assembly - Removal > Page 5062 Fluid Pressure Sensor/Switch: Service and Repair Transmission Solenoid and Pressure Switch Assembly - Installation INSTALLATION 1. Install the solenoid/pressure switch assembly. 2. Install mounting bolts (1) at clamp plate (2) and tighten to 6 Nm (50 in. lbs.). 3. Connect the electrical connectors (1, 2) to the pressure control solenoid and line pressure sensors. 4. Install valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5066 Transmission Position Switch/Sensor: Diagrams Connector (62TE) - (TRANSMISSION) 23 WAY ASSEMBLY-TRANSMISSION SOLENOID/TRS (62TE) - (TRANSMISSION) 23 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Removal 2. Remove the park rod assembly (2) from the TRS/rooster comb (1). 3. Remove the set screw (1) with a allen wrench (3) at manual lever (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5069 4. Remove the roll pin (3) at the TRS/rooster comb (1) using a pin punch (2). 5. Remove the manual lever (2) from case and inspect the bushing (3). 6. Remove the TRS/rooster (1, 2) comb from the case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5070 7. Remove the manual lever seal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5071 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install a new manual lever oil seal (2) using socket (3). 2. Install the manual lever in the case up to the point of the TRS. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5072 3. Install the TRS/rooser comb onto the manual lever and fully install the manual lever into the case. 4. Install the roll pin (3) to the TRS/rooster comb (1) using a pin punch (2). 5. Install the set screw (1) at manual lever (2) and tighten to 1 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5073 6. Install the park rod assembly (2) to the TRS/rooster comb (1) and place the park rod assembly into the guide assembly. 7. Place the park pawl pin into the park pawl tube. 8. Install the electrical connector. 9. Install the valve body See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 5078 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 5079 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-INPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 5082 Transmission Speed Sensor: Diagrams Output Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-OUTPUT SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (62TE) (Transmission) 2 Way > Page 5083 Transmission Speed Sensor: Diagrams Transfer Speed Sensor (62TE) (Transmission) 2 Way Connector (62TE) - (TRANSMISSION) 2 WAY SENSOR-TRANSFER SPEED (62TE) - (TRANSMISSION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5086 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Operation OPERATION The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5087 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5088 Transmission Speed Sensor: Description and Operation Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5089 Transmission Speed Sensor: Description and Operation Output Speed Sensor - Description DESCRIPTION The Output Speed Sensor (2) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Output Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Output Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5090 The output speed sensor (2) is located at the rear of the case. It reads the rotation of the underdrive compounder output carrier. Input Speed Sensor - Description DESCRIPTION The Input Speed Sensor (1) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5091 NOTE: Always use a new O-ring The Input Speed Sensor is bolted (1) to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Input Speed Sensor - Operation OPERATION The input speed sensor (1) is located at the top of the case, and read turbine speed from the input clutch hub. Transfer Shaft Speed Sensor - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5092 The Transfer Shaft Speed Sensor (3) is a two-wire magnetic pickup device that generates AC signals as rotation occurs. The Transfer Shaft Speed Sensor (1) is bolted to the transaxle case and uses a O-ring (2) to seal it to the transaxle case. Transfer Shaft Speed Sensor - Operation OPERATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Speed Sensor - Description > Page 5093 The transfer shaft speed sensor (3) is located at the rear of the case (backside). It reads rotation of the front annulus/rear carrier assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5096 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5097 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5098 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5099 Transmission Speed Sensor: Service and Repair Input Speed Sensor - Installation INSTALLATION 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5100 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5101 Transmission Speed Sensor: Service and Repair Output Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the output speed sensor (2). 2. Remove the bolt at output speed sensor (1). 3. Pull up on output speed sensor to remove. Output Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5102 1. Install a new O-ring (2). 2. Install output speed sensor (2) into case. 3. Install bolt at output speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5103 Input Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the input speed sensor (1). 2. Remove the bolt at input speed sensor. 3. Pull up on input speed sensor (1) to remove. Input Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5104 1. Install a new O-ring (2). 2. Install input speed sensor (1) into case. 3. Install bolt at input speed sensor and tighten to 12 Nm (105 in. lbs.). 4. Engage electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5105 Transfer Shaft Speed Sensor - Removal REMOVAL 1. Unplug the electrical connector at the transfer shaft sensor (3). 2. Remove the bolt at transfer shaft sensor (1). 3. Pull up on transfer shaft sensor to remove. Transfer Shaft Speed Sensor - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Speed Sensor - Removal > Page 5106 1. Install a new O-ring (2). on the transfer shaft speed sensor (1). 2. Install transfer shaft speed sensor (3) into case. 3. Install bolt at transfer shaft speed sensor (1) and tighten to 12 Nm (105 in. lbs.). 4. Reconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5112 Electronic Brake Control Module: Diagrams Connector - (HEADLAMP AND DASH) 47 WAY MODULE-ANTI-LOCK BRAKES - (HEADLAMP AND DASH) 47 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5113 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. NOTE: The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. For information on the ICU, See: Hydraulic Control Assembly - Antilock Brakes/Description and Operation/Integrated Control Unit (ICU) - Description - DESCRIPTION). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 5116 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - Illuminate the ESP function lamp in the message center on the instrument panel when a traction control event occurs. - Illuminate the ESP function lamp when the amber ABS warning indicator lamp illuminates. The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the ESP function lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - ESP/BAS warning indicator lamp - Diagnostic communication ABM OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication - ESP/BAS warning indicator lamp - Diagnostic communication Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Removal LEFT-HAND DRIVE NOTE: The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA. 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the engine appearance cover. 3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 4. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5119 6. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 7. Remove the wheelhouse brace (2). 8. Remove two screws, then remove the fresh air plenum. 9. Raise and support the vehicle. See: Maintenance 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) upward to near the top of the slots in the bracket, then snug one or both of the mounting screws (2) to hold the ICU in this position. 12. Lower the vehicle. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 13. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar(R) Brake Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5120 NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 14. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). 15. Remove the four screws (1) attaching the ABM (2) to the HCU. A Torx T20 bit approximately 2 inches long works well. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5121 CAUTION: When removing the ABM from the HCU, be sure to completely separate the two components (approximately 38 mm (1.5 inches)) before removing the ABM. Otherwise, damage to the pressure sensor or pump motor connection may result, requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 16. Separate the ABM (1) from the HCU (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5122 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Installation LEFT-HAND DRIVE 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5123 4. Align components and install the ABM (1) on the HCU (2). 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5124 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 6. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 7. Raise and support the vehicle. See: Maintenance 8. Loosen the two mounting screws (2) as necessary and allow the ICU (1) mounting bracket to slide down over the mounting screws and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). 9. Lower the vehicle. 10. Position the fresh air plenum and install the two mounting screws. 11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5125 12. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 13. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 14. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 15. Install the engine appearance cover. 16. Connect the negative cable on the battery negative post. 17. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during TCS and ESP events and to empty the low pressure accumulators during ABS events. NOTE: The HCU is not serviceable from the ICU for vehicles equipped with Hill Start Assist (HSA). For more information, See: Integrated Control Unit (ICU) - Description - DESCRIPTION) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description > Page 5130 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description > Page 5131 On Right-Hand-Drive vehicles, the ICU (1) is located in the engine compartment, mounted to the left side body frame rail and strut tower. The ABS with ESP(R) and All-Speed Traction Control ICU consists of the following components: the ABM, 8 (build/decay) solenoid valves, two traction control solenoid valves, two electronic shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. NOTE: The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA). The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. The ABM can be serviced without removing the entire assembly from the vehicle. For additional information on the ABM, See: Electronic Brake Control Module/Description and Operation/Anti-Lock Brake System Module - Description. For additional information on the HCU, See: Hydraulic Control unit (HCU) - Description - DESCRIPTION). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Hydraulic Control unit (HCU) - Installation INSTALLATION To install the HCU, assemble and install the ICU. See: Overhaul/Integrated Control Unit (ICU) Assembly See: Integrated Control Unit (ICU) - Installation Integrated Control Unit (ICU) - Removal LEFT-HAND-DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: If servicing the ABM only, See: Electronic Brake Control Module/Service and Repair/Anti-Lock Brake System Module - Removal 1. Disconnect and isolate battery negative cable from battery post. 2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover. 4. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 5. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5134 6. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). 7. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 8. Remove the wheelhouse brace (2). 9. Remove two screws, then remove the fresh air plenum. 10. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel. 11. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). 12. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5135 NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 13. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5136 14. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 15. Lift the ICU and mounting bracket (1) off the mounting screws (2). 16. Move the brake tubes around as necessary without bending them and remove the ICU with bracket. NOTE: The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA). 17. To separate the ABM from the HCU, See: Overhaul/Integrated Control Unit (ICU) Disassembly. Integrated Control Unit (ICU) - Installation LEFT-HAND-DRIVE 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5137 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. CAUTION: The brake tubes must be routed to the correct ports. Improper routing can lead to degraded or undesirable system performance including external brake fluid leaks. (1) Master Cylinder Secondary (2) Front Left - (3) Front Right - (4) Master Cylinder Primary - (5) Rear Left - (6) Rear Right Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5138 4. Install the four chassis brake tubes (2, 3, 5, 6) at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 6. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 7. Position the fresh air plenum and install the two mounting screws. 8. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). 9. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 10. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5139 11. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 12. Install the engine appearance cover. 13. Remove the brake pedal holding tool. 14. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 15. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. See: Brake Bleeding/Service and Repair c. Check for leaks. d. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5140 Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Hydraulic Control unit (HCU) - Removal REMOVAL NOTE: The HCU is not serviceable from the ICU for vehicles equipped with Hill Start Assist (HSA). To remove the HCU, the ICU must be removed and disassembled. See: Integrated Control Unit (ICU) - Removal See: Overhaul/Integrated Control Unit (ICU) - Disassembly Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5141 Hydraulic Control Assembly - Antilock Brakes: Overhaul Integrated Control Unit (ICU) - Assembly ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5142 4. Align components and install the ABM (1) on the HCU (2). 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5143 6. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.). 7. Install the ICU in the vehicle. See: Removal and Replacement/Integrated Control Unit (ICU) Installation Integrated Control Unit (ICU) - Disassembly DISASSEMBLY NOTE: The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA). 1. If necessary, remove the mounting pins from the ICU. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5144 2. Remove the four screws (1) attaching the ABM (2) to the HCU. 3. Separate the ABM (1) from the HCU (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 5148 Lateral Accelerometer: Diagrams Connector - (BODY) 4 WAY SENSOR-DYNAMICS - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 5149 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the lower instrument panel trim on each side of console below instrument panel. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5152 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 6. Perform the Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION MODULE-ASBM The ESP Off Switch (2) is part of the accessory switch bank module located in the center bezel (2) on the instrument panel above the radio. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal > Page 5158 Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test and make sure the ESP Off switch operates properly. See: Brake Bleeding/Service and Repair 6. Verify proper operation of all components controlled by the switch bank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5163 Wheel Speed Sensor: Locations Left Rear Wheel Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5164 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5165 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way Wheel Speed Sensor: Diagrams Left Rear Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-LEFT REAR - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 5168 Wheel Speed Sensor: Diagrams Right Rear Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-RIGHT REAR - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 5169 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 5170 Wheel Speed Sensor: Diagrams Right Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Description Front DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (2) is attached to a mounting boss on each front knuckle (3). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Rear DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. The rear wheel speed sensor (2) head is mounted to the rear hub and bearing (1). The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 5173 WSS air gaps are not adjustable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 5174 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Operation Front OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Rear OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. See: Maintenance 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5177 7. Remove the screw (2) securing the wheel speed sensor routing bracket (3) to the brake flex hose bracket (4). 8. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5). 9. Remove the mounting screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle and remove the sensor from the vehicle. Rear REMOVAL 1. Access and remove the rear brake rotor. See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5178 CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 2. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 3. Remove the wheel speed sensor routing clip (4) from the brake tube routing bracket (1). 4. Remove the wheel speed sensor cable from the routing clips (3) above the trailing arm. 5. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5179 6. Remove the screw (1) fastening the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3). 7. Remove the screw (2) securing the wheel speed sensor routing clamp (1) to the trailing link. 8. Disconnect the vehicle wiring harness (3) from the wheel speed sensor connector (2) on the body (1). 9. Disengage the wheel speed sensor connector from the routing clip fastened to the body using a screwdriver. Pull the connector forward off the routing clip. Or, if a NEW routing clip is available, remove the routing clip from the body with the connector attached. 10. Remove the wheel speed sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5180 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 3. Position the wheel speed sensor routing bracket (3) on the brake flex hose bracket (4) and install the mounting screw (2). Tighten the mounting screw to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5181 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 20 Nm (15 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5182 1. Slide the wheel speed sensor wiring connector (2) onto the routing clip mounted on the body until it locks into place or if a NEW routing clip is attached to the connector, push it into the mounting holes on the body. 2. Connect the vehicle wiring harness (3) to the wheel speed sensor connector (2). 3. Attach the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3) using the mounting screw (1). Tighten the mounting screw to 20 Nm (15 ft. lbs.). 4. Attach the wheel speed sensor routing clamp (1) to the trailing link using the mounting screw (2). Tighten the mounting screw to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5183 5. Apply bearing grease (supplied with part) to sensor head shaft and O-ring. CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 6. Pass the wheel speed sensor head through the hole in the brake shield, then push it into the mounting hole in hub and bearing (3) and align the mounting screw hole. 7. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). 8. Install the wheel speed sensor routing clip (4) in the brake tube routing bracket (1). 9. Install the wheel speed sensor cable into the routing clips (3) above the trailing arm. 10. Install brake rotor as well as all components necessary to access it. See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 11. Perform the ABS Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5187 Yaw Rate Sensor: Diagrams Connector - (BODY) 4 WAY SENSOR-DYNAMICS - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5188 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the lower instrument panel trim on each side of console below instrument panel. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5191 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 6. Perform the Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, See: CAUTION: Before removing the master cylinder reservoir cap, thoroughly clean the cap and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. Pressure bleeding the brakes is recommended, although the brakes may be manually bled or pressure bled. Refer to the appropriate following procedure. PRESSURE BLEEDING PROCEDURE Follow the pressure bleeder manufacturer's instructions for use of the pressure bleeding equipment. 1. Install Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the master cylinder fluid reservoir. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 3. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 4. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 5. Repeat this procedure at all the remaining bleeder screws. 6. Check and adjust brake fluid level to the FULL mark on the reservoir. 7. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. MANUAL BLEEDING PROCEDURE NOTE: To bleed the brakes manually, the aid of a helper will be required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5196 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. IPB CALIPER BRAKE BLEEDING PROCEDURE NOTE: The following procedure is normally only necessary if a rear brake caliper has been removed and installed, or replaced. Perform the following procedure on each rear brake caliper as necessary. 1. Raise and support vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5197 3. Remove the brake caliper lower guide pin bolt (1). 4. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 5. Remove the outboard pad (5) from the adapter bracket. 6. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 7. Slowly pump the brake pedal until the caliper fingers touch the outboard surface of the brake rotor. Release the pedal. 8. Remove the brake caliper lower guide pin bolt. 9. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 10. Reinstall the outboard pad in the adapter bracket. 11. Open the caliper bleeder screw at least one full turn. 12. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5198 e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 13. Close the bleeder screw. 14. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 15. Have a helper pump the brake pedal three or four times and hold it in the down position. 16. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 17. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 18. Repeat the previous three steps until all trapped air is removed. 19. Tighten the guide pin bolt to 35 Nm (26 ft. lbs.). 20. Repeat the above procedure on the opposite rear brake caliper as necessary. 21. Check brake pedal travel and feel. If pedal travel is still excessive or if the pedal feels excessively spongy, repeat the entire procedure as necessary. 22. Install the tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts to 135 Nm (100 ft. lbs.). 23. Lower the vehicle. 24. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5199 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. See: 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder fluid reservoir to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal Brake Pedal Assy: Service and Repair Brake and/or Accelerator Pedals - Removal LEFT-HAND-DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column opening cover. 3. Disconnect the wiring connector (4) at the stop lamp switch (3). 4. Remove the stop lamp switch wiring routing clip (1) from the brake pedal bracket (2). 5. Remove the stop lamp switch (2). Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008.See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5204 6. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 7. Slide the booster push rod (1) off the brake pedal pin (3). 8. Remove the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. 9. Remove the remaining nut (5) attaching the brake pedal (1) to the dash panel. 10. Remove the brake pedal (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5205 Brake Pedal Assy: Service and Repair Brake and/or Accelerator Pedals - Installation LEFT-HAND-DRIVE 1. Carefully install the brake pedal and bracket assembly (1) in the vehicle lining up the bracket with the power brake booster mounting studs and the stud (2) on the dash panel. 2. Install the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. Do not tighten the nuts at this time. 3. Install the remaining nut (5) attaching the brake pedal (1) to the dash panel. To tighten this nut (and the other four from the preceding step), refer to the following step. CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 4. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5206 5. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster push rod (1). 6. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. CAUTION: Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008. 7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5207 8. If not already performed, connect the wiring connector (4) at the stop lamp switch (3). 9. Attach the stop lamp switch wiring routing clip (1) at the brake pedal bracket (2). 10. If equipped, install the silencer pad below the instrument panel. 11. Connect the battery negative cable to its post on the battery. 12. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 13. Road test the vehicle to ensure proper operation of the brakes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Front CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Rear CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Front INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Rear INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5213 Brake Caliper: Removal and Replacement Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. See: Maintenance 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5214 4. Remove the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). There are two washers (4) that will come off with the banjo bolt. Discard the washers. They should not be reused. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Rear REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate battery negative cable from battery post. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5215 2. Using a brake pedal holding tool as shown, depress brake pedal past its first inch of travel and hold it in this position. Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. 3. Raise and support vehicle. See: Maintenance 4. Remove wheel mounting nuts (3), then tire and wheel assembly (1). 5. Manually release the parking brake cable tension. See: Parking Brake System/Service and Repair 6. Collapse the cable retainer fingers (2) at the end of the cable housing (3), then pull the cable housing out of the mounting bracket (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5216 7. Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand (1) upward and unhook it from the caliper lever (2). 8. Remove the banjo bolt (4) connecting the brake flex hose (3) to the brake caliper (1). There are two washers (2) that will come off with the banjo bolt. Discard the washers. They should not be reused. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 9. Remove two caliper guide pin bolts (1). 10. Slide the disc brake caliper (2) from the disc brake adapter bracket (3) and brake pads. Front Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5217 INSTALLATION 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 35 Nm (26 ft. lbs.). 4. Install the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). Install NEW brake hose washers (4) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 26 Nm (19 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5218 5. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Remove the brake pedal holding tool. 8. Bleed the caliper as necessary. See: Brake Bleeding/Service and Repair 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5219 CAUTION: When installing a NEW brake caliper it is necessary to bleed the brakes using a special procedure which has been integrated to this installation procedure. 1. Remove the outboard pad (5) from the adapter bracket. CAUTION: Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots. 2. Install the disc brake caliper (2) over the inboard brake pad on the brake caliper adapter bracket and the brake rotor. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Lightly tighten the guide pin bolts at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5220 4. Install the banjo bolt (4) connecting the brake flex hose (3) to the brake caliper (1). Be sure to install a NEW brake hose washer (2) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 26 Nm (19 ft. lbs.). 5. Access the interior of the vehicle, remove the brake pedal holder, then slowly pump the brake pedal until the rear caliper fingers touch the outboard surface of the brake rotor where the brake pad was removed. Release the pedal. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 6. Remove two caliper guide pin bolts (1). 7. Slide the disc brake caliper (2) from the disc brake adapter bracket (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5221 8. Reinstall the outboard pad (5) in the adapter bracket (3). 9. Open the caliper bleeder screw at least one full turn. 10. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 11. Close the bleeder screw. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5222 CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 12. Return the brake caliper back down over the adapter bracket into mounted position and install the guide pin bolts (1). Tighten both guide pin bolts to 35 Nm (26 ft. lbs.). NOTE: While bleeding air from the brake caliper in the following steps, be sure to monitor the fluid level in the master cylinder reservoir making sure it does not go dry. 13. Have a helper pump the brake pedal three or four times and hold it in the down position. 14. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 15. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 16. Repeat the previous three steps as necessary until all trapped air is removed. 17. If necessary, bleed remaining wheel circuits as necessary using normal bleeding procedure. See: Brake Bleeding/Service and Repair 18. Pull the parking brake cable strand (1) outward from the cable housing and hook it onto the caliper lever (2). 19. Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5223 20. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 21. Reconnect the parking brake cable equalizer and reset the cable tension. See: Parking Brake System/Service and Repair 22. Lower vehicle. 23. Connect battery negative (-) cable to battery post. 24. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake pads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5224 Brake Caliper: Overhaul Disc Brake Caliper - Disassembly DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. See: Removal and Replacement/Disc Brake Caliper - Removal NOTE: Before disassembling the brake caliper, clean and inspect it. See: Procedures/Disc Brake Caliper - Cleaning See: Procedures/Disc Brake Caliper - Inspection/Front WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it. CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5225 groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Disc Brake Caliper - Assembly ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. 2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5226 CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. See: Removal and Replacement/Disc Brake Caliper - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-003-11 > Feb > 11 > Brakes - Premature Front Brake Pad Wear Brake Pad: Customer Interest Brakes - Premature Front Brake Pad Wear NUMBER: 05-003-11 GROUP: Brakes DATE: February 18, 2011 SUBJECT: Brake Front Pad Lining Life OVERVIEW: This bulletin involves installing new brake linings and replacing both brake rotors as required. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built for the 2009 model year sold in U.S. and Canada (sales code YAA and YAC) markets only. SYMPTOM/CONDITION: Front brake pads may exhibit lining life complaints. DIAGNOSIS: 1. Remove both front tire and wheel assemblies. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information > 22 - Tires and Wheels > Removal 2. Using a Brake Lining Thickness Gauge or Brake Pad/Shoe Gauge, measure brake pad thickness. 3. Perform the repair procedure if the brake pad usable material measured at its thinnest point measures 4mm (0.1575 inches) or less. 4. If the brake pad assemblies do not require replacement reassemble the vehicle. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 22 - Tires and Wheels> Installation. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the front brake pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > 05 - Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Removal. 2. Remove any clips retaining the brake rotor to the wheel mounting studs. 3. Slide the brake rotor off the hub and bearing. 4. Clean the hub face to remove any dirt or corrosion where the rotor mounts. 5. Perform Step # 2 through Step # 4 on the opposite side of the vehicle. 6. Install brake rotors (p/n CNM2X252AB) over the studs on the hub and bearing on both sides of the vehicle. NOTE: Rotor replacement is recommended when switching to this type brake pad. Standard brake service procedures apply thereafter. 7. Install new pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > O05 - Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-003-11 > Feb > 11 > Brakes - Premature Front Brake Pad Wear > Page 5235 Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Installation. POLICY: Reimbursable within the provisions of the warranty. Vehicles included in this Service Bulletin have a Warranty Extension for this repair. See Warranty Bulletins; U.S. D-11-07, Canada CA-2011-05 for details associated with the extended warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-003-11 > Feb > 11 > Brakes - Premature Front Brake Pad Wear Brake Pad: All Technical Service Bulletins Brakes - Premature Front Brake Pad Wear NUMBER: 05-003-11 GROUP: Brakes DATE: February 18, 2011 SUBJECT: Brake Front Pad Lining Life OVERVIEW: This bulletin involves installing new brake linings and replacing both brake rotors as required. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built for the 2009 model year sold in U.S. and Canada (sales code YAA and YAC) markets only. SYMPTOM/CONDITION: Front brake pads may exhibit lining life complaints. DIAGNOSIS: 1. Remove both front tire and wheel assemblies. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information > 22 - Tires and Wheels > Removal 2. Using a Brake Lining Thickness Gauge or Brake Pad/Shoe Gauge, measure brake pad thickness. 3. Perform the repair procedure if the brake pad usable material measured at its thinnest point measures 4mm (0.1575 inches) or less. 4. If the brake pad assemblies do not require replacement reassemble the vehicle. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 22 - Tires and Wheels> Installation. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the front brake pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > 05 - Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Removal. 2. Remove any clips retaining the brake rotor to the wheel mounting studs. 3. Slide the brake rotor off the hub and bearing. 4. Clean the hub face to remove any dirt or corrosion where the rotor mounts. 5. Perform Step # 2 through Step # 4 on the opposite side of the vehicle. 6. Install brake rotors (p/n CNM2X252AB) over the studs on the hub and bearing on both sides of the vehicle. NOTE: Rotor replacement is recommended when switching to this type brake pad. Standard brake service procedures apply thereafter. 7. Install new pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > O05 - Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-003-11 > Feb > 11 > Brakes - Premature Front Brake Pad Wear > Page 5241 Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Installation. POLICY: Reimbursable within the provisions of the warranty. Vehicles included in this Service Bulletin have a Warranty Extension for this repair. See Warranty Bulletins; U.S. D-11-07, Canada CA-2011-05 for details associated with the extended warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 5242 Brake Pad: Specifications Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Front CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Rear CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Front INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5245 Rear INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5246 Brake Pad: Removal and Replacement Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance NOTE: Perform 2 through 5 on each side of the vehicle to complete pad set removal. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Remove the two brake caliper guide pin bolts (2, 3). 4. Remove the disc brake caliper (4) from the disc brake adapter bracket (1) and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5247 5. Remove the brake pads (4, 5) from the caliper adapter bracket (2). Rear REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support vehicle. See: Maintenance NOTE: Perform 2 through 5 on each side of vehicle to complete pad set removal. 2. Remove wheel mounting nuts (3), then tire and wheel assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5248 CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Remove two caliper guide pin bolts (1). 4. Remove the disc brake caliper (2) from the disc brake adapter bracket (3) and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose or parking brake cable when doing this. 5. Remove the brake pads (2, 5) from the caliper adapter bracket (3). Front INSTALLATION NOTE: Perform 1 through 5 on each side of the vehicle to complete pad set installation, then proceed to 6. NOTE: Make sure that the audible wear indicator (if equipped) is placed toward the top when the inboard brake pad is installed on each side of the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5249 NOTE: If the brake pads have a protective paper on the rear face of the brake pad plate, it must be removed before pad installation. 1. Place the brake pads (4, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (2) as shown. Place the pad with the wear indicator (if equipped) attached on the inboard side (2). 2. Completely retract the caliper piston back into the bore of the caliper. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the boots. 3. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 4. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5250 5. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Rear INSTALLATION NOTE: Perform 1 through 6 on each side of vehicle to complete pad set installation, then proceed to 7. CAUTION: Anytime the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism. 1. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5251 2. Make sure abutment shims (4) are in place on both upper and lower slide abutments of caliper adapter (3). NOTE: If the brake pads have a protective paper on the rear face of the brake pad plate, it must be removed before pad installation. 3. Place the brake pads (2, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (3) as shown. CAUTION: Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots. 4. Install the disc brake caliper (2) over the brake pads on the brake caliper adapter bracket (3). CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 5. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Tighten the guide pin bolts to 35 Nm (26 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5252 6. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower vehicle. 8. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle. 9. Check and adjust brake fluid level as necessary. 10. Road test vehicle and make several stops to wear off any foreign material on brakes and to seat brake pads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-003-11 > Feb > 11 > Brakes Premature Front Brake Pad Wear Brake Rotor/Disc: Customer Interest Brakes - Premature Front Brake Pad Wear NUMBER: 05-003-11 GROUP: Brakes DATE: February 18, 2011 SUBJECT: Brake Front Pad Lining Life OVERVIEW: This bulletin involves installing new brake linings and replacing both brake rotors as required. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built for the 2009 model year sold in U.S. and Canada (sales code YAA and YAC) markets only. SYMPTOM/CONDITION: Front brake pads may exhibit lining life complaints. DIAGNOSIS: 1. Remove both front tire and wheel assemblies. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information > 22 - Tires and Wheels > Removal 2. Using a Brake Lining Thickness Gauge or Brake Pad/Shoe Gauge, measure brake pad thickness. 3. Perform the repair procedure if the brake pad usable material measured at its thinnest point measures 4mm (0.1575 inches) or less. 4. If the brake pad assemblies do not require replacement reassemble the vehicle. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 22 - Tires and Wheels> Installation. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the front brake pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > 05 - Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Removal. 2. Remove any clips retaining the brake rotor to the wheel mounting studs. 3. Slide the brake rotor off the hub and bearing. 4. Clean the hub face to remove any dirt or corrosion where the rotor mounts. 5. Perform Step # 2 through Step # 4 on the opposite side of the vehicle. 6. Install brake rotors (p/n CNM2X252AB) over the studs on the hub and bearing on both sides of the vehicle. NOTE: Rotor replacement is recommended when switching to this type brake pad. Standard brake service procedures apply thereafter. 7. Install new pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > O05 - Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-003-11 > Feb > 11 > Brakes Premature Front Brake Pad Wear > Page 5261 Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Installation. POLICY: Reimbursable within the provisions of the warranty. Vehicles included in this Service Bulletin have a Warranty Extension for this repair. See Warranty Bulletins; U.S. D-11-07, Canada CA-2011-05 for details associated with the extended warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-003-11 > Feb > 11 > Brakes - Premature Front Brake Pad Wear Brake Rotor/Disc: All Technical Service Bulletins Brakes - Premature Front Brake Pad Wear NUMBER: 05-003-11 GROUP: Brakes DATE: February 18, 2011 SUBJECT: Brake Front Pad Lining Life OVERVIEW: This bulletin involves installing new brake linings and replacing both brake rotors as required. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built for the 2009 model year sold in U.S. and Canada (sales code YAA and YAC) markets only. SYMPTOM/CONDITION: Front brake pads may exhibit lining life complaints. DIAGNOSIS: 1. Remove both front tire and wheel assemblies. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information > 22 - Tires and Wheels > Removal 2. Using a Brake Lining Thickness Gauge or Brake Pad/Shoe Gauge, measure brake pad thickness. 3. Perform the repair procedure if the brake pad usable material measured at its thinnest point measures 4mm (0.1575 inches) or less. 4. If the brake pad assemblies do not require replacement reassemble the vehicle. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 22 - Tires and Wheels> Installation. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the front brake pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > 05 - Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Removal. 2. Remove any clips retaining the brake rotor to the wheel mounting studs. 3. Slide the brake rotor off the hub and bearing. 4. Clean the hub face to remove any dirt or corrosion where the rotor mounts. 5. Perform Step # 2 through Step # 4 on the opposite side of the vehicle. 6. Install brake rotors (p/n CNM2X252AB) over the studs on the hub and bearing on both sides of the vehicle. NOTE: Rotor replacement is recommended when switching to this type brake pad. Standard brake service procedures apply thereafter. 7. Install new pads. Refer to the service information outlined in DealerCONNECT > TechCONNECT > Service Information tab > 05 - Brakes > O05 - Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-003-11 > Feb > 11 > Brakes - Premature Front Brake Pad Wear > Page 5267 Brakes, Base, Brake > Hydraulic/Mechanical > PADS, Brake, Front > Installation. POLICY: Reimbursable within the provisions of the warranty. Vehicles included in this Service Bulletin have a Warranty Extension for this repair. See Warranty Bulletins; U.S. D-11-07, Canada CA-2011-05 for details associated with the extended warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5268 Brake Rotor/Disc: Specifications SPECIFICATIONS NOTE: When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning (machining) equipment is required. LIMITS/SPECIFICATIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5269 Brake Rotor/Disc: Testing and Inspection BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. See: Service and Repair/Procedures. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness (1) at the center of the brake pad contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5270 Minimum thickness specifications are cast on the rotor's un-machined surface (1). Limits can also be found in this component's specification table. See: Specifications ROTOR THICKNESS VARIATION Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor (2) at 12 equal points around the rotor braking surface with a micrometer (1) at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary beyond the specification listed in the specification table See: Specifications , the rotor should be refaced or replaced. See: Service and Repair/Procedures. ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the brake rotor (hub runout can be measured separately). To measure rotor runout on the vehicle: 1. Raise and support the vehicle. See: Maintenance 2. Remove the tire and wheel assembly. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Removal 3. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross (star) pattern to 135 Nm (100 ft. lbs.). NOTE: Dial Indicator, Special Tool 9524, can be used in conjunction with C-3339A to measure in millimeters instead of inches. Dial indicator Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5271 9524 includes a finer scale to measure lower, tighter tolerances. 4. Mount Dial Indicator (1), Special Tool C-3339A, with Wheel, Special Tool 25w, or equivalent, to the knuckle. Position the dial indicator wheel to contact the rotor braking surface approximately 10 millimeters from the outer edge of the rotor (3). 5. Slowly rotate the brake rotor checking lateral runout, marking the low and high spots. Record these measurements. 6. Check and record the runout on the opposite side of the rotor in the same fashion, marking the low and high spots. 7. Compare runout measurement to specifications.See: Specifications If runout is in excess of specifications, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor (1) and the one wheel stud (2) closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. 8. Remove the rotor from the hub. See: Service and Repair/Removal and Replacement/Brake Rotor - Removal NOTE: Before measuring hub runout, clean the hub face surface with an appropriate cleaner. This provides a clean surface to get an accurate indicator reading. NOTE: Dial Indicator, Special Tool 9524, can be used in conjunction with C-3339A to measure in millimeters instead of inches. Dial indicator 9524 includes a finer scale to measure lower, tighter tolerances. 9. Mount Dial Indicator (2), Special Tool C-3339A, to the knuckle. Position the dial indicator stem so it contacts the hub face (1) near the outer diameter. Care must be taken to position the stem outside of the stud circle, but inside of the chamfer on the hub rim. 10. Slowly rotate the hub measuring runout. Hub runout should not exceed 0.01 mm (0.0004 inch). If runout exceeds this specification, the hub must be replaced. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Removal See: Maintenance/Wheels and Tires/Wheel Bearing/Service and Repair/Rear Hub and Bearing - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5272 11. If hub runout does not exceed this specification, install the original rotor back on the hub, aligning the chalk mark on the rotor (2) with a wheel mounting stud, two studs apart from the original stud (1). 12. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross (star) pattern to 135 Nm (100 ft. lbs.). 13. Mount the Dial Indicator (1), Special Tool C-3339A, and remeasure runout on both sides of the brake rotor as explained in earlier steps to see if runout is now within specifications. See: Specifications 14. If runout is still not within specifications, reface or replace brake rotor. See: Service and Repair/Procedures Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe (1), or replaced. The use of a hub-mounted on-car brake lathe (1) is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. NOTE: All brake rotors (2) have markings for minimum allowable thickness cast on an un-machined surface of the rotor (1) or stamped into the hat section. Minimum thickness specifications can also be found in this component's specification table. See: Specifications Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Specifications for brake rotor machining can be founds specification table. See: Specifications Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5275 Brake Rotor/Disc: Removal and Replacement Front FRONT NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. 3. Remove the two bolts (3) securing disc brake caliper and adapter bracket (1) to the steering knuckle (2). 4. Remove the disc brake caliper and adapter bracket (1) from the knuckle (2) and rotor (4) as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5276 5. Remove any clips retaining the brake rotor to the wheel mounting studs. 6. Slide the brake rotor (2) off the hub and bearing (1). Rear REAR NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5277 3. Remove two bolts (1) securing the disc brake caliper and adapter bracket ( 2) to the knuckle (3). 4. Remove the disc brake caliper and adapter bracket (2) as an assembly from the knuckle (3) and rotor. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove any retaining clips, then slide the brake rotor (2) off the hub and bearing (1). Front FRONT NOTE: Inspect disc brake pads before installation, See: Brake Pad/Service and Repair/Procedures/Brake Pads - Inspection/Front . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5278 1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the brake rotor (2) over the studs on the hub and bearing. 3. Install the disc brake caliper and adapter bracket assembly (1) over the brake rotor (4) and knuckle (2). 4. Install the mounting bolts (3) securing the caliper adapter bracket to the knuckle (2). Tighten the bolts to 169 Nm (125 ft. lbs.). 5. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor. Rear REAR NOTE: Inspect disc brake pads before installation. Replace as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5279 1. Clean the rotor mounting face of the hub and bearing (1) to remove any dirt or corrosion. 2. Install the brake rotor (2) over the hub and bearing (1). CAUTION: If the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism. 3. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5280 4. Install the disc brake caliper and adapter bracket (2) over the knuckle and rotor as an assembly. 5. Install the two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle. Tighten the mounting bolts to 100 Nm (74 ft. lbs.). 6. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving vehicle. 9. Check and adjust the brake fluid level as necessary. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, See: CAUTION: Before removing the master cylinder reservoir cap, thoroughly clean the cap and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. Pressure bleeding the brakes is recommended, although the brakes may be manually bled or pressure bled. Refer to the appropriate following procedure. PRESSURE BLEEDING PROCEDURE Follow the pressure bleeder manufacturer's instructions for use of the pressure bleeding equipment. 1. Install Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the master cylinder fluid reservoir. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 3. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 4. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 5. Repeat this procedure at all the remaining bleeder screws. 6. Check and adjust brake fluid level to the FULL mark on the reservoir. 7. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. MANUAL BLEEDING PROCEDURE NOTE: To bleed the brakes manually, the aid of a helper will be required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5286 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. IPB CALIPER BRAKE BLEEDING PROCEDURE NOTE: The following procedure is normally only necessary if a rear brake caliper has been removed and installed, or replaced. Perform the following procedure on each rear brake caliper as necessary. 1. Raise and support vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5287 3. Remove the brake caliper lower guide pin bolt (1). 4. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 5. Remove the outboard pad (5) from the adapter bracket. 6. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 7. Slowly pump the brake pedal until the caliper fingers touch the outboard surface of the brake rotor. Release the pedal. 8. Remove the brake caliper lower guide pin bolt. 9. Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket. 10. Reinstall the outboard pad in the adapter bracket. 11. Open the caliper bleeder screw at least one full turn. 12. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5288 e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 13. Close the bleeder screw. 14. Return the caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt finger tight. 15. Have a helper pump the brake pedal three or four times and hold it in the down position. 16. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 17. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 18. Repeat the previous three steps until all trapped air is removed. 19. Tighten the guide pin bolt to 35 Nm (26 ft. lbs.). 20. Repeat the above procedure on the opposite rear brake caliper as necessary. 21. Check brake pedal travel and feel. If pedal travel is still excessive or if the pedal feels excessively spongy, repeat the entire procedure as necessary. 22. Install the tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts to 135 Nm (100 ft. lbs.). 23. Lower the vehicle. 24. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 5289 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. See: 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder fluid reservoir to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Front CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Rear CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Front INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Rear INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5294 Brake Caliper: Removal and Replacement Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. See: Maintenance 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5295 4. Remove the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). There are two washers (4) that will come off with the banjo bolt. Discard the washers. They should not be reused. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Rear REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate battery negative cable from battery post. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5296 2. Using a brake pedal holding tool as shown, depress brake pedal past its first inch of travel and hold it in this position. Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. 3. Raise and support vehicle. See: Maintenance 4. Remove wheel mounting nuts (3), then tire and wheel assembly (1). 5. Manually release the parking brake cable tension. See: Parking Brake System/Service and Repair 6. Collapse the cable retainer fingers (2) at the end of the cable housing (3), then pull the cable housing out of the mounting bracket (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5297 7. Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand (1) upward and unhook it from the caliper lever (2). 8. Remove the banjo bolt (4) connecting the brake flex hose (3) to the brake caliper (1). There are two washers (2) that will come off with the banjo bolt. Discard the washers. They should not be reused. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 9. Remove two caliper guide pin bolts (1). 10. Slide the disc brake caliper (2) from the disc brake adapter bracket (3) and brake pads. Front Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5298 INSTALLATION 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 35 Nm (26 ft. lbs.). 4. Install the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). Install NEW brake hose washers (4) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 26 Nm (19 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5299 5. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Remove the brake pedal holding tool. 8. Bleed the caliper as necessary. See: Brake Bleeding/Service and Repair 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5300 CAUTION: When installing a NEW brake caliper it is necessary to bleed the brakes using a special procedure which has been integrated to this installation procedure. 1. Remove the outboard pad (5) from the adapter bracket. CAUTION: Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots. 2. Install the disc brake caliper (2) over the inboard brake pad on the brake caliper adapter bracket and the brake rotor. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Lightly tighten the guide pin bolts at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5301 4. Install the banjo bolt (4) connecting the brake flex hose (3) to the brake caliper (1). Be sure to install a NEW brake hose washer (2) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 26 Nm (19 ft. lbs.). 5. Access the interior of the vehicle, remove the brake pedal holder, then slowly pump the brake pedal until the rear caliper fingers touch the outboard surface of the brake rotor where the brake pad was removed. Release the pedal. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 6. Remove two caliper guide pin bolts (1). 7. Slide the disc brake caliper (2) from the disc brake adapter bracket (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5302 8. Reinstall the outboard pad (5) in the adapter bracket (3). 9. Open the caliper bleeder screw at least one full turn. 10. Seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. 11. Close the bleeder screw. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5303 CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots. CAUTION: When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head. 12. Return the brake caliper back down over the adapter bracket into mounted position and install the guide pin bolts (1). Tighten both guide pin bolts to 35 Nm (26 ft. lbs.). NOTE: While bleeding air from the brake caliper in the following steps, be sure to monitor the fluid level in the master cylinder reservoir making sure it does not go dry. 13. Have a helper pump the brake pedal three or four times and hold it in the down position. 14. With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any. 15. Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal. 16. Repeat the previous three steps as necessary until all trapped air is removed. 17. If necessary, bleed remaining wheel circuits as necessary using normal bleeding procedure. See: Brake Bleeding/Service and Repair 18. Pull the parking brake cable strand (1) outward from the cable housing and hook it onto the caliper lever (2). 19. Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5304 20. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 21. Reconnect the parking brake cable equalizer and reset the cable tension. See: Parking Brake System/Service and Repair 22. Lower vehicle. 23. Connect battery negative (-) cable to battery post. 24. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake pads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5305 Brake Caliper: Overhaul Disc Brake Caliper - Disassembly DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. See: Removal and Replacement/Disc Brake Caliper - Removal NOTE: Before disassembling the brake caliper, clean and inspect it. See: Procedures/Disc Brake Caliper - Cleaning See: Procedures/Disc Brake Caliper - Inspection/Front WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it. CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5306 groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Disc Brake Caliper - Assembly ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. 2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5307 CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. See: Removal and Replacement/Disc Brake Caliper - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5312 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5313 Brake Fluid: Specifications Brake Master Cylinder .......................................................................................................................................... Mopar DOT 3, SAE J1703 or equivalent If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5314 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar(R) Brake Fluid or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5315 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5316 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECKING NOTE: Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. See: Specifications NOTE: Although there is a range, the preferred level is FULL. 1. Remove the cap. 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir as necessary. Do not overfill the system. 3. Install the cap. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5320 Brake Fluid Level Sensor/Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-BRAKE FLUID LEVEL - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5321 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) that hold the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal > Page 5324 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Tubes and Hoses - Description Brake Hose/Line: Description and Operation Brake Tubes and Hoses - Description DESCRIPTION The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses used at each wheel brake are made of reinforced rubber with fittings at each end. The fitting at each brake caliper is the banjo-type and requires a special banjo bolt and copper washers. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Tubes and Hoses - Description > Page 5329 Brake Hose/Line: Description and Operation Brake Tubes and Hoses - Operation OPERATION The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The flex hoses are made of rubber to allow for the movement of the vehicle's suspension. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 5330 Brake Hose/Line: Service and Repair INSPECTION Brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible brake hoses should be performed whenever the brake system is serviced and every 12,000 km (7,500 miles) or 12 months, whichever comes first. Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the hose becomes exposed due to cracks or abrasions in the hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. NOTE: This vehicle is equipped with more than one size (diameter) brake tube depending on location on the vehicle. If a brake tube must be replaced, always use the same size brake tubing as that being replaced. Never use under-size brake tubing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during TCS and ESP events and to empty the low pressure accumulators during ABS events. NOTE: The HCU is not serviceable from the ICU for vehicles equipped with Hill Start Assist (HSA). For more information, See: Integrated Control Unit (ICU) - Description - DESCRIPTION) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 5335 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 5336 On Right-Hand-Drive vehicles, the ICU (1) is located in the engine compartment, mounted to the left side body frame rail and strut tower. The ABS with ESP(R) and All-Speed Traction Control ICU consists of the following components: the ABM, 8 (build/decay) solenoid valves, two traction control solenoid valves, two electronic shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. NOTE: The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA). The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. The ABM can be serviced without removing the entire assembly from the vehicle. For additional information on the ABM, See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Description and Operation/Anti-Lock Brake System Module - Description. For additional information on the HCU, See: Hydraulic Control unit (HCU) - Description DESCRIPTION). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 5337 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Operation OPERATION For operation of the ICU, refer to the individual components of the ICU. - ANTILOCK BRAKE MODULE (ABM) See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Description and Operation/Anti-Lock Brake System Module - Description - HYDRAULIC CONTROL UNIT (HCU) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Hydraulic Control unit (HCU) - Installation INSTALLATION To install the HCU, assemble and install the ICU. See: Overhaul/Integrated Control Unit (ICU) Assembly See: Integrated Control Unit (ICU) - Installation Integrated Control Unit (ICU) - Removal LEFT-HAND-DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: If servicing the ABM only, See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair/Anti-Lock Brake System Module - Removal 1. Disconnect and isolate battery negative cable from battery post. 2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover. 4. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 5. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5340 6. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). 7. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 8. Remove the wheelhouse brace (2). 9. Remove two screws, then remove the fresh air plenum. 10. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel. 11. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5341 12. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7). NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 13. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5342 14. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 15. Lift the ICU and mounting bracket (1) off the mounting screws (2). 16. Move the brake tubes around as necessary without bending them and remove the ICU with bracket. NOTE: The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA). 17. To separate the ABM from the HCU, See: Overhaul/Integrated Control Unit (ICU) Disassembly. Integrated Control Unit (ICU) - Installation LEFT-HAND-DRIVE 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5343 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. CAUTION: The brake tubes must be routed to the correct ports. Improper routing can lead to degraded or undesirable system performance including external brake fluid leaks. (1) Master Cylinder Secondary (2) Front Left - (3) Front Right - (4) Master Cylinder Primary - (5) Rear Left - (6) Rear Right Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5344 4. Install the four chassis brake tubes (2, 3, 5, 6) at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 6. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 7. Position the fresh air plenum and install the two mounting screws. 8. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). 9. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 10. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5345 11. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 12. Install the engine appearance cover. 13. Remove the brake pedal holding tool. 14. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 15. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. See: Brake Bleeding/Service and Repair c. Check for leaks. d. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5346 Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Hydraulic Control unit (HCU) - Removal REMOVAL NOTE: The HCU is not serviceable from the ICU for vehicles equipped with Hill Start Assist (HSA). To remove the HCU, the ICU must be removed and disassembled. See: Integrated Control Unit (ICU) - Removal See: Overhaul/Integrated Control Unit (ICU) - Disassembly Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5347 Hydraulic Control Assembly - Antilock Brakes: Overhaul Integrated Control Unit (ICU) - Assembly ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5348 4. Align components and install the ABM (1) on the HCU (2). 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5349 6. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.). 7. Install the ICU in the vehicle. See: Removal and Replacement/Integrated Control Unit (ICU) Installation Integrated Control Unit (ICU) - Disassembly DISASSEMBLY NOTE: The HCU and the ABM are not serviceable separately from the ICU for vehicles equipped with Hill Start Assist (HSA). 1. If necessary, remove the mounting pins from the ICU. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5350 2. Remove the four screws (1) attaching the ABM (2) to the HCU. 3. Separate the ABM (1) from the HCU (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder - Description Brake Master Cylinder: Description and Operation Brake Master Cylinder - Description DESCRIPTION All master cylinders (2) are a two-outlet design and the brake tubes from these primary and secondary outlet ports lead directly to the Integrated Control Unit (ICU) before going to each wheel brake. All master cylinders mount to the power brake booster in the same manner. The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and also has threaded ports with seats for hydraulic brake tube connections. The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake fluid to the master cylinder when it is required. On manual transmission model vehicles the brake fluid reservoir also feeds the clutch hydraulic circuit. The reservoir is made of see-through plastic and it houses the brake fluid level switch. A removable brake fluid level switch is mounted in the right side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder - Description > Page 5355 Brake Master Cylinder: Description and Operation Brake Master Cylinder - Operation OPERATION When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake pressure through the chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly. The master cylinder's outlet ports supply hydraulic pressure to the Integrated Control Unit (ICU) where it is distributed to the individual wheel brakes. The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on both sides of the diaphragm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise with soft-jaw caps. 2. Thread a Bleeder Tube (2), Special Tool 8358-1, into the primary and secondary ports. Tighten bleeder tube nuts to 17 Nm (150 in. lbs.). 3. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure. 4. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent. See: Brake Fluid/Specifications 5. Using an appropriately sized wooden dowel as a pushrod (1), slowly press the pistons inward discharging brake fluid through the Bleeder Tubes (2), then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. See: Removal and Replacement/Brake Master Cylinder Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5358 Brake Master Cylinder: Removal and Replacement Brake Master Cylinder - Removal LEFT-HAND-DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . CAUTION: The vacuum in the power brake booster must be depleted before removing the master cylinder to avoid damaging the master cylinder and to prevent inhalation of the o-ring or any other contamination into the booster. The preferred method is to pump the brake pedal while the engine is not running until the brake pedal becomes firm. An alternative method is to remove and immediately reinstall the check valve located on the booster. If the check valve is removed, special care should be taken to ensure that the grommet is not damaged and remains seated, the check valve is dry and free of debris, and that contaminates cannot be ingested during removal. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 4. Disconnect the primary (1) and secondary (3) brake tubes at the master cylinder (2) outlet ports. Install plugs at all of the open brake tube outlets on the master cylinder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5359 5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1). 6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or an equivalent. 7. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 8. Slide the master cylinder straight out of the power brake booster. Brake Master Cylinder - Installation LEFT-HAND-DRIVE NOTE: The master cylinder must be bled before installing it on the vehicle. 1. Bench bleed the master cylinder. See: Procedures 2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5360 CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum O-ring seal (2) MUST be installed on the master cylinder mounting flange (1). 3. If the master cylinder does not have a new vacuum O-ring seal (2) on the mounting flange (1), remove it. Install a NEW vacuum O-ring seal on the master cylinder mounting flange making sure the O-ring fits evenly against the mounting flange. CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 4. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster. 5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5361 6. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3). 7. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. 8. Connect the primary (1) and secondary (3) brake tubes to the master cylinder (2) outlet ports. Tighten the tube nuts to 17 Nm (150 in. lbs.). 9. Connect the wiring harness connector (1) to the brake fluid level switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5362 10. Connect the negative (ground) cable on the battery. 11. Fill the master cylinder reservoir to the proper level. See: Brake Fluid/Service and Repair WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. See: Brake Bleeding/Service and Repair 12. Road test the vehicle to ensure proper operation of the brakes. Brake Master Cylinder Reservoir - Removal REMOVAL CAUTION: If at any time the master cylinder is loosened or removed, you must perform the master cylinder installation procedure to ensure that the seal (o-ring) is still on the hub of the master cylinder See: Brake Master Cylinder Installation . NOTE: The brake fluid level switch is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir See: Brake Fluid Level Sensor/Switch/Service and Repair/Brake Fluid Level Switch - Removal NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the outer and inner cowl covers See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover Removal See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Removal 2. Remove the front wiper motor module See: Wiper and Washer Systems/Wiper Motor Linkage/Service and Repair/Wiper Arm Linkage - Removal 3. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar(R) Brake Parts Cleaner or equivalent. 4. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 5. Remove the brake fluid reservoir cap. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. 6. Remove the four reservoir retaining tabs from the mounting posts on the master cylinder housing. 7. Pull the reservoir straight up and remove it from the grommet seals in master cylinder housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5363 Brake Master Cylinder Reservoir - Installation INSTALLATION NOTE: The brake fluid level switch is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir See: Brake Fluid Level Sensor/Switch/Service and Repair/Brake Fluid Level Switch - Installation 1. Lubricate the reservoir mounting area with fresh clean brake fluid. With the grommet seals (2) on the fluid reservoir spigots, place the reservoir in position over the master cylinder. Install the fluid reservoir by firmly pressing down on the fluid reservoir. Once installed, make sure the fluid reservoir is touching the top of both grommet seals. 2. Push the reservoir retaining tabs over the mounting posts on the master cylinder housing. Make sure the retaining tabs are securely engaged. 3. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent See: Brake Fluid/Specifications 4. Install the front wiper motor module See: Wiper and Washer Systems/Wiper Motor Linkage/Service and Repair/Wiper Arm Linkage - Installation 5. Install the inner and outer cowl covers See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover Installation See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5364 Brake Master Cylinder: Overhaul Brake Master Cylinder - Disassembly DISASSEMBLY NOTE: If the reservoir is being replaced, the new reservoir will come with a brake fluid level switch installed. The old fluid switch does not need to be transferred from the old reservoir to the new reservoir. 1. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar(R) Brake Parts Cleaner or equivalent. 2. Remove the brake fluid reservoir cap. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. 3. Remove the four reservoir retaining tabs from the mounting posts on the master cylinder housing. 4. Pull the reservoir straight up and remove it from the grommet seals in master cylinder housing. 5. Remove the vacuum O-ring seal (2) from the master cylinder mounting flange (1). Brake Master Cylinder - Assembly ASSEMBLY NOTE: If the reservoir is being replaced, the new reservoir will come with a brake fluid level switch installed. The old fluid switch does not need to be transferred from the old reservoir to the new reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5365 1. Install a NEW vacuum O-ring seal (2) on the master cylinder mounting flange (1) making sure the O-ring fits evenly against the mounting flange. 2. Lubricate the reservoir mounting area with fresh clean brake fluid. With the grommet seals (2) on the fluid reservoir spigots, place the reservoir in position over the master cylinder. Install the fluid reservoir by firmly pressing down on the fluid reservoir. Once installed, make sure the fluid reservoir is touching the top of both grommet seals. 3. Push the reservoir retaining tabs over the mounting posts on the master cylinder housing. Make sure the retaining tabs are securely engaged. 4. Fill and thoroughly bleed the master cylinder before installing it. See: Procedures 5. Install the master cylinder. See: Removal and Replacement/Brake Master Cylinder - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise Parking Brake Cable: Customer Interest Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 5375 b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 5376 CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise Parking Brake Cable: All Technical Service Bulletins Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 5382 b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 5383 CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal Parking Brake Cable: Service and Repair Removal Front Cable - With Foot Lever WITH FOOT LEVER 1. Release the parking brake. 2. Raise and support the vehicle. See: Maintenance 3. Manually release the parking brake cable tension. See: Service and Repair 4. Collapse the front cable retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the cable (5) forward and remove it from the intermediate bracket. 5. Push the front cable strand into the housing until it bottoms. 6. Remove the nuts (5) securing the front cable routing clamps (1) to the underbody of the vehicle. 7. Remove the cable routing clamps (1) from the cable (4). 8. Lower the vehicle. 9. Remove the left front door opening sill scuff plate. 10. Remove the lower cowl trim. 11. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5386 12. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1). 13. Pull the parking brake lever pedal up and hold it in this position. 14. Rotate the cable strand around at the lever mechanism until the strand lines up with the slot, then remove the cable end button (2) from the lever mechanism (1). NOTE: Prior to removing cable from lever, note cable routing through lever for ease in reassembly. 15. Collapse the front cable retainer fingers on the end of the cable housing (1) at the lever (2). 16. Remove the cable from the parking brake lever (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5387 17. Lift back the carpet and pull the cable seal loose from the floor pan. 18. Remove the front parking brake cable from the vehicle through the hole in the floor pan. Front Cable - With Hand Lever WITH HAND LEVER 1. Remove the floor center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal 2. Manually release the parking brake cable tension. See: Service and Repair 3. Raise and support the vehicle. See: Maintenance 4. Remove the parking brake cable equalizer/bent nail tensioner (4) from the three parking brake cables (2, 3, 5). 5. Collapse the front cable retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the cable (5) forward and remove it from the intermediate bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5388 6. Remove the screws (4) securing the front cable routing clamps (1, 5) to the underbody of the vehicle. 7. Remove the cable routing clamps (1, 5) from the cable (6). 8. Lower the vehicle. 9. Remove the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). 10. Remove the adjusting nut (2) from the end of the front parking brake cable. 11. Remove the cable strand from the lever. 12. Pull the cable seal loose from the floor pan and remove the front parking brake cable from the vehicle through the access hole in the floor pan. Rear Cable REMOVAL 1. Release the parking brake. 2. Manually release the parking brake cable tension. See: Service and Repair 3. Raise and support the vehicle. See: Maintenance Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5389 4. Remove wheel mounting nuts (3), then tire and wheel assembly (1). 5. If not removed, remove the cable equalizer (4) (with foot lever) or equalizer/tensioner (with hand lever) from the front and rear cables. 6. Collapse the right rear cable (3) retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the right rear cable out of the intermediate bracket. 7. Pull the right rear cable (2) out of the cable routing loop (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5390 8. If servicing the left rear cable, collapse the left rear cable (2) retainer fingers at the end of the cable housing where it contacts the intermediate bracket (1). Pull the left rear cable out of the intermediate bracket. 9. If servicing the left rear cable, remove the nuts (1) fastening the cable routing loop (3) to the vehicle underbody near the trailing link forward mounting point. 10. If servicing the right rear cable, remove the four screws securing the right rear cable to the rear crossmember . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5391 11. If servicing the right rear cable, remove the upper bolt (1) securing the knuckle to the trailing link. This bolt also fastens the cable routing clamp (3) in place. 12. If servicing the left rear cable: a. Remove the upper bolt (1) securing the knuckle to the trailing link as well as the rear cable routing clamp (3). b. Remove the other bolt (2) fastening the rear cable (4) to the trailing arm. 13. Collapse the cable retainer fingers (2) at the end of the cable housing (3), then pull the cable housing out of the mounting bracket (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5392 14. Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand (1) upward and unhook it from the caliper lever (2). 15. Remove the cable from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5393 Parking Brake Cable: Service and Repair Installation Front Cable - With Foot Lever WITH FOOT LEVER 1. Pass most of the front parking brake cable down through the access hole in the floor pan from inside the vehicle. 2. Insert the lever end of the front parking brake cable through the mounting hole in the parking brake lever (2). Slide it through until the cable retainer fingers on the end of the housing (1) lock in place. Make sure all fingers are engaged preventing removal of the cable from the bracket. 3. Pull the button on the end of cable strand out of housing and route the strand around the cable guide, then rotate the cable strand up and align the cable with the slot in lever mechanism (1). Slide the cable button (2) into the slot and rotate the cable down into mounted position with the cable inserted into the guide on the mechanism. 4. Slide any extra cable back into the cable housing. This can be easily done by pulling on the trailing end of the front cable strand that is now under the vehicle. 5. Install the front parking brake cable floor pan seal into the access hole in the floor pan. 6. Reposition the carpeting back down on the floor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5394 7. Install the steering column cover reinforcement (1) using the four mounting screws (2). 8. Install the steering column opening cover. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation 9. Install the lower cowl trim. 10. Install the left front door opening sill scuff plate. 11. Raise and support the vehicle. 12. Pass the end of the front cable (5) through the hole in the end of the intermediate bracket (1). Press the cable housing retainer through the hole until the fingers on the retainer lock it into place. 13. Install the cable routing clamps (1) over the metal sleeves on the front cable (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5395 14. Position the front cable routing clamps over the studs on the underbody of the vehicle and install the nuts (5). Tighten the nuts to 6 Nm (55 in. lbs.). 15. Reconnect the parking brake cable equalizer (4) and reset the cable tension. See: Service and Repair 16. Lower the vehicle. 17. Apply and release the parking brake lever (pedal) one time. This will seat the parking brake cables. 18. Check operation of parking brakes. Front Cable - With Hand Lever WITH HAND LEVER 1. Pass most of the front parking brake cable down through the access hole in the floor pan from inside the vehicle. 2. Install the front parking brake cable floor pan seal into the access hole in the floor pan. 3. Install the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). Tighten the mounting screws to 28 Nm (21 ft. lbs.). 4. Route the cable strand around the lever cable guide and start the adjusting nut (2) on the end of the cable stud. Do not install the nut any further than having the threads flush with the top of the nut. Otherwise, cable equalizer/bent nail tensioner installation later in this procedure could be difficult. 5. Slide any extra cable back into the cable housing. 6. Raise and support the vehicle. See: Maintenance Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5396 7. Install the cable routing clamps (1, 5) over the metal sleeves on the front cable (6). Be sure to place the correct length clamp at the appropriate location. 8. Position the front cable routing clamps over the studs on the underbody of the vehicle and install the screws (4). Tighten the screws to 6 Nm (55 in. lbs.). 9. Pass the end of the front cable (5) through the hole in the end of the intermediate bracket (1). Press the cable housing retainer through the hole until the fingers on the retainer lock it into place. 10. Connect the parking brake cable equalizer/bent nail tensioner (4) to the three parking brake cables (2, 3, 5). 11. Remove any slack from the parking brake cables by pushing the front cable strand forward into the housing until slack is removed. 12. Lower the vehicle. 13. Reset the hand lever cable tension and verify check operation of the parking brake. See: Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5397 14. Install the cover on the side of the parking brake lever. 15. Install the floor center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Rear Cable INSTALLATION 1. Guide the trailing end of the parking brake cable along the inboard side of the axle trailing arm up to the rear brake caliper. Make sure the cable is routed between the brake line and the trailing arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5398 2. Pull the parking brake cable strand (1) outward from the cable housing and hook it onto the caliper lever (2). 3. Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket. CAUTION: Before installing bolt (1) in the following step, it is especially important to clean the threads and apply Mopar(R) Lock & Seal Adhesive or equivalent. 4. If servicing the left rear cable, position the cable routing clamps (3) against the axle trailing link and: a. Install the upper mounting bolt (1) securing the trailing link (and cable routing clamp) to the knuckle. Tighten the mounting bolt to 60 Nm (44 ft. lbs.). b. Install the bolt (2) attaching the other cable routing clamp to the axle trailing link. Tighten the bolt to 28 Nm (21 ft. lbs.). CAUTION: Before installing bolt (1) in the following step, it is especially important to clean the threads and apply Mopar(R) Lock & Seal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5399 Adhesive or equivalent. 5. If servicing the right rear cable, position the cable routing clamps (3) against the axle trailing link and install the upper mounting bolt (1) securing the trailing link (and cable routing clamp) to the knuckle. Tighten the mounting bolt to 60 Nm (44 ft. lbs.). 6. If servicing the right rear cable, route the cable over the rear axle (if equipped with AWD) along the front of the rear suspension crossmember. Position the four routing clamps on the rear crossmember and install the screws. Tighten the screws to 6 Nm (55 in. lbs.). . 7. If servicing the left rear cable, place the routing loop (3) over the studs on the vehicle underbody near the trailing link forward mounting point and install the mounting nuts. Tighten the nuts to 6 Nm (55 in. lbs.). 8. Insert the right rear cable (2) through the lower loop of the cable routing loop (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5400 9. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. If servicing the left rear cable, pass the leading end of the left rear cable (2) through the upper hole in the intermediate bracket (1). Press the cable housing through the hole until the fingers on the retainer lock it into place. 11. If servicing a vehicle equipped with a foot lever: a. Connect the parking brake cable equalizer (4) to the three parking brake cables (2, 3, 5) and reset the cable tension. See: Service and Repair b. Lower the vehicle. 12. If servicing a vehicle equipped with a hand lever: a. Connect the parking brake cable equalizer/bent nail tensioner (4) to the three parking brake cables (2, 3, 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5401 b. Remove any slack from the parking brake cables by pushing the front cable strand forward into the housing until slack is removed. c. Lower the vehicle. d. Reset the hand lever cable tension and verify check operation of the parking brake. See: Service and Repair 13. Check operation of parking brakes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal Parking Brake Lever: Service and Repair Removal Foot Operated Parking Brake Lever FOOT OPERATED PARKING BRAKE LEVER 1. Release the parking brake. 2. Raise and support the vehicle. See: Maintenance 3. Manually release the parking brake cable tension. See: Service and Repair 4. Push the front cable strand into the housing until it bottoms. 5. Lower the vehicle. 6. Remove the left front door opening sill scuff plate. 7. Remove the lower cowl trim. 8. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 9. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1). 10. Pull the parking brake lever pedal up and hold it in this position. 11. Rotate the cable strand around at the lever mechanism until the strand lines up with the slot, then remove the cable end button (2) from the lever mechanism (1). NOTE: Prior to removing cable from lever, note cable routing through lever for ease in reassembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5406 12. Collapse the front cable retainer fingers on the end of the cable housing (1) at the lever (2). 13. Remove the cable from the parking brake lever (3). 14. Disconnect the wiring connector (2) at parking brake indicator lamp switch. 15. Remove the three mounting nuts (2), then remove the parking brake lever (1) from the cowl (3). Hand Operated Parking Brake Lever HAND OPERATED PARKING BRAKE LEVER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5407 1. Remove the floor center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal 2. Manually release the parking brake cable tension. See: Service and Repair 3. Remove the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). 4. Remove the adjusting nut (2) from the end of the front parking brake cable. 5. Remove the cable strand from the lever. 6. Disconnect the wiring connector (2) at parking brake indicator lamp switch (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5408 7. Remove the two horizontal (5) and one vertical (2) mounting bolts, then remove the parking brake lever (1) from the shifter bracket (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5409 Parking Brake Lever: Service and Repair Installation Foot Operated Parking Brake Lever FOOT OPERATED PARKING BRAKE LEVER 1. Position the parking brake lever (1) over the mounting studs, against the left lower cowl (3). 2. Install the three mounting nuts (2). Tighten the nuts to 28 Nm (21 ft. lbs.). 3. Connect the wiring connector (2) at the parking brake indicator lamp switch on the parking brake lever (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5410 4. Insert the lever end of the front parking brake cable through the mounting hole in the parking brake lever (2). Slide it through until the cable retainer fingers on the end of the housing (1) lock in place. Make sure all fingers are engaged preventing removal of the cable from the bracket. 5. Pull the button on the end of cable strand out of housing and route the strand around the cable guide, then rotate the cable strand up and align the cable with the slot in lever mechanism (1). Slide the cable button (2) into the slot and rotate the cable down into mounted position with the cable inserted into the guide on the mechanism. 6. Slide any extra cable back into the cable housing. This can be easily done by pulling on the trailing end of the front cable strand that is now under the vehicle. 7. Install the front parking brake cable floor pan seal into the access hole in the floor pan. 8. Reposition the carpeting back down on the floor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5411 9. Install the steering column cover reinforcement (1) using the four mounting screws (2). 10. Install the steering column opening cover. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation 11. Install the lower cowl trim. 12. Install the left front door opening sill scuff plate. 13. Raise and support the vehicle. See: Maintenance 14. If the original parking brake lever is being reinstalled, reconnect the parking brake cable equalizer (4) and reset the cable tension. See: Service and Repair 15. If a NEW parking brake lever is being installed, connect the parking brake cable equalizer to the cables, then remove the pin locking the lever mechanism spring tension at the lever. 16. Lower the vehicle. 17. Apply and release the parking brake lever (pedal) one time. This will seat the parking brake cables. 18. Check operation of parking brake lever and parking brakes. Hand Operated Parking Brake Lever HAND OPERATED PARKING BRAKE LEVER 1. Position the parking brake lever (1) on the shifter bracket (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5412 NOTE: When installing the vertical mounting bolt in the following step make sure to capture the ground strap (2) with the mounting bolt (1) before installation. 2. Install the two horizontal (5) and one vertical (2) mounting bolts. Tighten the nuts to 20 Nm (15 ft. lbs.). 3. Connect the wiring connector (2) at the parking brake indicator lamp switch (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5413 4. Install the mounting screws (3) fastening the front cable (4) to the side of the parking brake lever (1). Tighten the mounting screws to 28 Nm (21 ft. lbs.). 5. Route the cable strand around the lever cable guide and start the adjusting nut (2) on the end of the cable stud. Do not install the nut any further than having the threads flush with the top of the nut before the next step is performed. 6. Make sure the cables (2, 3, 5) are connected to the cable equalizer/bent nail tensioner (4) at the intermediate bracket (1) under the vehicle. 7. Reset the hand lever cable tension and verify check operation of the parking brake. See: Service and Repair 8. Install the cover on the side of the parking brake lever. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 5414 9. Install the floor center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5418 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5419 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a foot-operated or hand-operated park brake lever mechanism. FOOT-OPERATED Foot-Operated Park Brake Switch The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED Hand-Operated Park Brake Switch The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 5422 connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 5423 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Page 5424 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5427 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5428 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5429 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation DESCRIPTION The power brake booster (3) is mounted to the engine side of the dash panel. The master cylinder is bolted to the front of the booster. A vacuum check valve is also mounted on the front of the booster. A vacuum line connects the check valve to engine source vacuum. The booster input rod extends through the dash panel and connects to the brake pedal. This vehicle uses a tandem diaphragm, single rate vacuum power brake booster with 203 and 229 mm (8 and 9 in.) diaphragms. Power brake boosters are internally tuned differently depending on whether the vehicle is equipped with ABS or without ABS. If the power brake booster requires replacement, be sure it is replaced with the correct part. The power brake booster can be identified by the tag attached to the body of the booster. This tag contains the following information: - The production part number - The date it was built, and - The booster manufacturer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5434 Vacuum Brake Booster: Testing and Inspection POWER BRAKE BOOSTER BASIC TEST 1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. (6.8 to 11.3 kg) pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches Hg, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches, the hose or check to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST 1. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 2. Start the engine. 3. Allow the engine to warm up to normal operating temperature and engine idle. 4. Using vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test. 5. Remove the pliers from the hose temporarily. 6. Apply light effort (approximately 15 lbs. (6.8 kg) of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 7. Have an assistant reattach the pliers to the vacuum supply hose. 8. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal Vacuum Brake Booster: Service and Repair Power Brake Booster - Removal LEFT-HAND-DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 4. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5437 6. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 7. Remove the wheelhouse brace (2). 8. Remove the master cylinder. See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder - Removal 9. Disconnect the rear brake tubes (1) at the junction block (2). Install plugs at all of the open brake tubes. 10. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5438 11. If equipped, remove the silencer pad below the steering column opening cover. 12. Remove the stop lamp switch (2). Do not reuse the stop lamp switch on vehicles built prior to July 21, 2008.See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal 13. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 14. Slide the booster push rod (1) off the brake pedal pin (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5439 15. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel. 16. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5440 Vacuum Brake Booster: Service and Repair Power Brake Booster - Installation LEFT-HAND-DRIVE NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs. 1. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position. 2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5441 CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). 4. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1). 5. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. CAUTION: Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008. 6. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation 7. If equipped, install the silencer pad below the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5442 CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces. 8. Connect the vacuum hose (2) to the vacuum check valve (1). 9. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 Nm (150 in. lbs.). 10. Install the master cylinder. See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder Installation 11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5443 12. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 13. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 14. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 15. Connect the battery negative cable to its post on the battery. 16. Bleed the base brake system. See: Brake Bleeding/Service and Repair 17. Road test the vehicle to ensure proper operation of the brakes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5448 Electronic Brake Control Module: Diagrams Connector - (HEADLAMP AND DASH) 47 WAY MODULE-ANTI-LOCK BRAKES - (HEADLAMP AND DASH) 47 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5449 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. NOTE: The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. For information on the ICU, See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Description and Operation/Integrated Control Unit (ICU) - Description - DESCRIPTION). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description > Page 5452 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - Illuminate the ESP function lamp in the message center on the instrument panel when a traction control event occurs. - Illuminate the ESP function lamp when the amber ABS warning indicator lamp illuminates. The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the ESP function lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - ESP/BAS warning indicator lamp - Diagnostic communication ABM OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication - ESP/BAS warning indicator lamp - Diagnostic communication Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Removal LEFT-HAND DRIVE NOTE: The ABM is only separately serviceable for non-HSA (Hill Start Assist) equipped vehicles. Do not remove the ABM for vehicles equipped with HSA. 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the engine appearance cover. 3. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 4. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 5. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5455 6. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 7. Remove the wheelhouse brace (2). 8. Remove two screws, then remove the fresh air plenum. 9. Raise and support the vehicle. See: Maintenance 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) upward to near the top of the slots in the bracket, then snug one or both of the mounting screws (2) to hold the ICU in this position. 12. Lower the vehicle. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 13. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar(R) Brake Parts Cleaner or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5456 NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 14. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be pulled straight outward off the ABM (1). 15. Remove the four screws (1) attaching the ABM (2) to the HCU. A Torx T20 bit approximately 2 inches long works well. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5457 CAUTION: When removing the ABM from the HCU, be sure to completely separate the two components (approximately 38 mm (1.5 inches)) before removing the ABM. Otherwise, damage to the pressure sensor or pump motor connection may result, requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 16. Separate the ABM (1) from the HCU (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5458 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Installation LEFT-HAND DRIVE 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5459 4. Align components and install the ABM (1) on the HCU (2). 5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5460 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 6. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 7. Raise and support the vehicle. See: Maintenance 8. Loosen the two mounting screws (2) as necessary and allow the ICU (1) mounting bracket to slide down over the mounting screws and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). 9. Lower the vehicle. 10. Position the fresh air plenum and install the two mounting screws. 11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5461 12. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 13. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 14. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 15. Install the engine appearance cover. 16. Connect the negative cable on the battery negative post. 17. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Perform the ABS Verification Test and road test the vehicle. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5466 Brake Fluid Level Sensor/Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-BRAKE FLUID LEVEL - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5467 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir. The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) that hold the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal > Page 5470 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 5474 Lateral Accelerometer: Diagrams Connector - (BODY) 4 WAY SENSOR-DYNAMICS - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 5475 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the lower instrument panel trim on each side of console below instrument panel. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5478 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 6. Perform the Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5482 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5483 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a foot-operated or hand-operated park brake lever mechanism. FOOT-OPERATED Foot-Operated Park Brake Switch The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED Hand-Operated Park Brake Switch The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 5486 connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 5487 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 5488 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5491 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5492 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5493 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION MODULE-ASBM The ESP Off Switch (2) is part of the accessory switch bank module located in the center bezel (2) on the instrument panel above the radio. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal > Page 5499 Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test and make sure the ESP Off switch operates properly. See: Brake Bleeding/Service and Repair 6. Verify proper operation of all components controlled by the switch bank. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5504 Wheel Speed Sensor: Locations Left Rear Wheel Speed Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5505 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5506 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way Wheel Speed Sensor: Diagrams Left Rear Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-LEFT REAR - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 5509 Wheel Speed Sensor: Diagrams Right Rear Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-RIGHT REAR - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 5510 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Rear Wheel Speed Sensor (Body) 2 Way > Page 5511 Wheel Speed Sensor: Diagrams Right Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Description Front DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (2) is attached to a mounting boss on each front knuckle (3). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Rear DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. The rear wheel speed sensor (2) head is mounted to the rear hub and bearing (1). The encoder is integral to the hub and bearing assembly. The encoder is serviced as part of the rear hub and bearing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 5514 WSS air gaps are not adjustable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 5515 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Operation Front OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Rear OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. See: Maintenance 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5518 7. Remove the screw (2) securing the wheel speed sensor routing bracket (3) to the brake flex hose bracket (4). 8. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5). 9. Remove the mounting screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle and remove the sensor from the vehicle. Rear REMOVAL 1. Access and remove the rear brake rotor. See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5519 CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 2. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 3. Remove the wheel speed sensor routing clip (4) from the brake tube routing bracket (1). 4. Remove the wheel speed sensor cable from the routing clips (3) above the trailing arm. 5. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5520 6. Remove the screw (1) fastening the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3). 7. Remove the screw (2) securing the wheel speed sensor routing clamp (1) to the trailing link. 8. Disconnect the vehicle wiring harness (3) from the wheel speed sensor connector (2) on the body (1). 9. Disengage the wheel speed sensor connector from the routing clip fastened to the body using a screwdriver. Pull the connector forward off the routing clip. Or, if a NEW routing clip is available, remove the routing clip from the body with the connector attached. 10. Remove the wheel speed sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5521 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 3. Position the wheel speed sensor routing bracket (3) on the brake flex hose bracket (4) and install the mounting screw (2). Tighten the mounting screw to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5522 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 20 Nm (15 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5523 1. Slide the wheel speed sensor wiring connector (2) onto the routing clip mounted on the body until it locks into place or if a NEW routing clip is attached to the connector, push it into the mounting holes on the body. 2. Connect the vehicle wiring harness (3) to the wheel speed sensor connector (2). 3. Attach the wheel speed sensor routing clamp (2) to the rear suspension crossmember (3) using the mounting screw (1). Tighten the mounting screw to 20 Nm (15 ft. lbs.). 4. Attach the wheel speed sensor routing clamp (1) to the trailing link using the mounting screw (2). Tighten the mounting screw to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5524 5. Apply bearing grease (supplied with part) to sensor head shaft and O-ring. CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 6. Pass the wheel speed sensor head through the hole in the brake shield, then push it into the mounting hole in hub and bearing (3) and align the mounting screw hole. 7. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). 8. Install the wheel speed sensor routing clip (4) in the brake tube routing bracket (1). 9. Install the wheel speed sensor cable into the routing clips (3) above the trailing arm. 10. Install brake rotor as well as all components necessary to access it. See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 11. Perform the ABS Verification Test and clear any faults. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 5528 Yaw Rate Sensor: Diagrams Connector - (BODY) 4 WAY SENSOR-DYNAMICS - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 5529 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). The Dynamics Sensor (1) is located on the floor tunnel just forward of the center floor console (2), below the instrument panel. Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the lower instrument panel trim on each side of console below instrument panel. 3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Working on each side of the floor tunnel, remove the nuts (2) mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5532 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Working on each side of the floor pan tunnel (4), install the two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness connector (3) to the dynamics sensor (1). 4. Install the lower instrument panel trim on each side of console below the instrument panel. 5. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 6. Perform the Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations Ignition Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations > Page 5538 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Ignition Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Ignition Switch: Connector Views Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 5558 Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Operation OPERATION Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a spring-loaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY,""RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS) Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Operation. REMOTE KEYLESS ENTRY (RKE) The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Operation TIRE PRESSURE MONITORING (TPM) The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Operation. REMOTE START WITH/EXTENDED RANGE ANTENNA Further information concerning the Remote Start System. See: Starting System/Keyless Starting System/Description and Operation/Starting System - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI) The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. PARK SHIFT INTERLOCK The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 5559 Ignition Switch: Description and Operation Ignition Switch - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN). The WIN, along with the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch located on the face of the instrument panel just to the inboard side of the steering column. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. In addition to replacing a conventional keyed ignition switch, the WIN is an integrated electronic receiver that serves as the base station in the vehicle. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) RF communication. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged the entire WIN must be replaced See: Service and Repair/Wireless Ignition Node Receiver - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ignition Switch: Symptom Related Diagnostic Procedures FOBIK TRAPPED IN WIN The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 5. Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. 6. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. 7. Remove the lower WIN attaching screw (5). 8. Remove the lower WIN bracket attaching screw (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 5564 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 5565 Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Installation INSTALLATION NOTE: The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening. 2. Install the lower WIN bracket attaching screw (4). 3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 5566 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Install knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker Installation. 9. Connect negative battery cable. 10. If necessary, program the WIN, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5570 Neutral Safety Switch: Diagrams Connector (MTX) - (BODY) 3 WAY SWITCH-CLUTCH INTERLOCK (MTX) - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5575 Starter Relay: Diagrams Connector - (IN TIPM) 5 WAY RELAY-STARTER - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair JUMP STARTING WARNING: Do not jump start a frozen battery, personal injury can result. Do not jump start a vehicle when the battery fluid is below the top of lead plates. Do not allow jumper cable clamps to touch each other when connected to a booster source. Do not use open flame near battery. Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Refer to instructions provided with device being used. Failure to follow these instructions may result in personal injury or death. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. NOTE: For information on accessing the battery for service or replacement See: Service and Repair/Removal and Replacement/Battery Removal TO JUMP START A DISABLED VEHICLE: WARNING: - Take care to avoid the radiator cooling fan whenever the hood is raised. It can start anytime the ignition switch is ON. You can be hurt by the fan. - Do not attempt to push or tow your vehicle to get it started. Vehicles equipped with an automatic transaxle cannot be started this way. Unburned fuel could enter the catalytic converter and once the engine has started, ignite and damage the converter and vehicle. If the vehicle has a discharged battery, booster cables may be used to obtain a start from another vehicle. This type of start can be dangerous if done improperly, so follow this procedure carefully. - Do not use a booster battery or any other booster source with an output that exceeds 12 Volts. WARNING: - Battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin, or clothing. Don't lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush contaminated area immediately with large quantities of water. - A battery generates hydrogen gas, which is flammable and explosive. Keep flame or spark away from the vent holes. NOTE: The battery is stored in a compartment that is located behind the left front fender and is accessible through the wheel well. Remote jump-start terminals are located in the engine compartment. 1. Wear eye protection and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. 2. When boosting from a battery in another vehicle, park that vehicle within booster cable reach, but without allowing the vehicles to touch. Set parking brake, place automatic transaxle in PARK, and turn ignition to LOCK for both vehicles. WARNING: Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result. 3. Turn off the heater, radio, and all unnecessary electrical loads. 4. Remove the protective cover (1) over the remote jump-start positive battery post (2) (+) in the engine compartment. Connect one end of the jumper Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 5580 cable to the positive battery post (2). Connect the other end of the same cable to the positive terminal of the booster battery. 5. Connect the other cable, first to the negative terminal of the booster battery and then to the engine ground (-) of the vehicle with the discharged battery (5). Make sure you have a good contact on the engine ground. 6. If the vehicle is equipped with Sentry Key Immobilizer, turn the ignition switch to the ON position for three seconds before moving the ignition switch to the START position. 7. Start the engine in the vehicle that has the booster battery, let the engine idle a few minutes, and then start the engine in the vehicle with the discharged battery. 8. When removing the jumper cables, reverse the sequence exactly. Be careful of the moving belts and fan. 9. Reinstall the protective cover over the remote jump-start positive battery post. WARNING: During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting jump-start. WARNING: Any procedure other than above could result in: - Personal injury caused by electrolyte squirting out the battery vent; - Personal injury or property damage due to battery explosion; Damage to charging system of booster vehicle or of immobilized vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description Battery Cable: Description and Operation Battery Cables - Description DESCRIPTION The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then soldered. The battery positive cable wires feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a smaller female battery terminal clamp. There are two separate battery cable harnesses used on this vehicle. The battery harness includes both the battery positive and negative cables to the remote battery connection and may include portions of the wiring circuits for other components on some vehicles. The starter harness includes both the battery positive and negative cables from the remote battery connection down to the starter and engine ground location. These two harnesses are sold as separate assemblies. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description > Page 5585 Battery Cable: Description and Operation Battery Cables - Operation OPERATION The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Totally Integrated Power Module (TIPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a ground connection, typically on the engine cylinder block. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5586 Battery Cable: Testing and Inspection BATTERY CABLES A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and load tested. Refer to Standard Procedures for the proper battery charging and load test procedures. See: Service and Repair/Procedures/Battery Charging - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay can be found in the Junction Block located in the left front engine compartment area. See the layout label affixed to the underside of the Junction Block cover for ASD relay identification and location. 1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. 2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5587 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid B(+) terminal stud (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal Battery Cable: Service and Repair Battery Cables - Removal REMOVAL BATTERY HARNESS WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. 1. Disconnect and isolate the negative battery cable (2) remote terminal from the remote battery post (1). 2. Raise vehicle on hoist See: Maintenance. 3. Remove the battery and set aside See: Service and Repair/Removal and Replacement/Battery - Removal. 4. On diesel engine equipped vehicles, disconnect the in-line connector to the instrument panel harness (2) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5590 NOTE: Diesel battery harness shown, gasoline battery harness similar. 5. Lower the vehicle. 6. Remove the negative battery cable remote terminal nut (8) from the remote negative battery post. Remove the battery harness negative cable (7) from the remote negative battery post. 7. Remove the cover (1) from the remote positive battery terminal (2). Remove the starter harness positive cable retaining nut (4) and remove the cable (3) from the remote positive battery post. 8. Remove the remote positive battery terminal (2) from mounting bracket on the left strut tower (15) by lifting straight up. 9. On diesel engine equipped vehicles: - Disconnect the glow plug module connector (14) - Disconnect the cabin heater relay connectors (11 and 13) - Disconnect the in-line connector to the instrument panel harness (12) 10. Remove the retaining nut (1) and remove the battery harness cable (2) from the TIPM stud. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5591 11. Depress the four mounting clips (2) to disengage and remove the TIPM housing (1) from its mounting bracket, position aside to allow access to the battery harness. 12. One at a time, trace any remaining battery harness retaining push pins, fasteners and routing clips until the harness is free from the vehicle. 13. Remove the battery harness from the vehicle. STARTER HARNESS 1. Remove the negative battery cable remote terminal nut (5) from the remote negative battery post (1). Remove and isolate the battery harness negative cable (4) on something other than the remote negative battery post (1). 2. Remove the starter harness negative cable retaining nut (3) and remove the cable (2) from the remote negative battery post (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5592 3. Remove the cover (1) from the remote positive battery terminal. Remove the starter harness positive cable retaining nut (4) and remove the cable (3) from the remote positive battery post (2). 4. Raise vehicle on hoist, See: Maintenance. 5. Remove the starter harness negative cable retaining bolt (4) and remove the cable (5) from the engine block. 6. Remove the starter harness positive cable retaining nut (6) and remove the cable (2) from the starter positive battery post. 7. One at a time, trace any remaining starter harness retaining pushpins, fasteners and routing clips until the harness is free from the vehicle. 8. Remove the starter harness (3) from the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5593 Battery Cable: Service and Repair Battery Cables - Installation INSTALLATION BATTERY HARNESS 1. Position the battery harness into the vehicle. 2. One at a time, install the battery harness retaining pushpins, fasteners and routing clips until the harness is installed exactly where it was in the vehicle. 3. Position the battery harness cable (2) onto the TIPM stud (3). Install the retaining nut (1) and tighten to 10 Nm (90 in. lbs.) 4. Install the TIPM on the bracket posts, push down until you hear a click. NOTE: Diesel battery harness shown, gasoline battery harness similar. 5. On diesel engine equipped vehicles: - Connect the glow plug module connector (14) - Connect the cabin heater relay connectors (11 and 13) - Connect the in-line connector to the instrument panel harness (12) 6. Install the remote positive battery terminal (2) onto the mounting bracket on the left strut tower (15) by pushing straight down until fully engaged. 7. Remove the cover (1) from the remote positive battery terminal (2). Position the starter harness positive cable (3) onto the remote positive battery Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5594 post. Install the retaining nut (4) and tighten to 16.5 Nm (145 in. lbs.) Install the cover (1) onto the remote positive battery terminal (2). 8. Raise vehicle on hoist, See: Maintenance. 9. Install the battery See: Service and Repair/Removal and Replacement/Battery - Installation. 10. Lower the vehicle. 11. Install the negative battery cable remote terminal (2) onto the remote battery post (1). Install the nut (3) and tighten to 16.5 Nm (145 in. lbs.) STARTER HARNESS WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5595 1. Remove and isolate the battery harness negative cable (4) on something other than the remote negative battery post (1). 2. Position the starter harness into the vehicle. 3. One at a time, install the starter harness retaining pushpins, fasteners and routing clips until the harness is installed exactly where it was in the vehicle. 4. Position the starter harness negative cable (2) onto the remote negative battery post (1). Install the retaining nut (3) and tighten to 16.5 Nm (145 in. lbs.) Remove the cover (1) from the remote positive battery terminal (2). Position the starter harness positive cable (3) onto the remote positive battery post. Install the retaining nut (4) and tighten to 16.5 Nm (145 in. lbs.) Install the cover (1) onto the remote positive battery terminal (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 5596 5. Raise vehicle on hoist, See: Maintenance. 6. Position the starter harness positive cable (2) onto the starter positive battery post. Install the retaining nut (6) and tighten to 13 Nm (115 in. lbs.) 7. Position the starter harness negative cable (5) onto the engine block. Install the retaining bolt (4) and tighten to 16.5 Nm (145 in. lbs.) 8. Lower the vehicle. 9. Position the negative battery harness cable remote terminal (4) onto the remote battery post (1). Install the nut (5) and tighten to 16.5 Nm (145 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Description and Operation Battery Tray: Description and Operation DESCRIPTION The battery is placed and secured in a stamped steel battery tray. The battery tray is located in the left front side of the vehicle, just ahead of the left front wheel and tire assembly. The battery tray is secured to the left front frame rail with four bolts. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray - Removal Battery Tray: Service and Repair Battery Tray - Removal REMOVAL WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. 1. Disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Remove the battery See: Service and Repair/Removal and Replacement/Battery - Removal. 3. Remove the four bolts (2) securing the battery tray (3) to the left front frame rail (1). 4. Remove the battery tray from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray - Removal > Page 5602 Battery Tray: Service and Repair Battery Tray - Installation INSTALLATION WARNING: To protect the hands from battery acid, a suitable pair of heavy duty rubber gloves should be worn when removing or servicing a battery. Safety glasses also should be worn. WARNING: Remove metallic jewelry to avoid injury by accidental arcing of battery current. CAUTION: The negative battery cable remote terminal (2) must be disconnected and isolated from the remote battery post (1) prior to service of the vehicle electrical systems. The negative battery cable remote terminal can be isolated by using the supplied isolation hole (3) in the terminal casing. 1. Position the battery tray (3) onto the left front frame rail (1). 2. Install the bolts (2) securing the battery tray (3) to the frame rail (1).Tighten the bolts to 16 Nm (142 in. lbs.) 3. Install the battery See: Service and Repair/Removal and Replacement/Battery - Installation. 4. Install the negative battery cable remote terminal onto the remote battery post. Tighten the nut to 16.5 Nm (145 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Negative Remote Jump Post (3.5L Ground Eyelet) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Negative Remote Jump Post (3.5L Ground Eyelet) > Page 5607 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Negative Remote Jump Post (3.5L Ground Eyelet) > Page 5608 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Negative Remote Jump Post (3.5L Ground Eyelet) > Page 5609 Remote Battery Jumper Terminal: Locations Positive Remote Jump Post (3.5L Starter Eyelet) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Negative Remote Jump Post (3.5L Ground Eyelet) > Page 5610 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Negative Remote Jump Post (3.5L Ground Eyelet) > Page 5611 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Diagrams > Negative Remote Jump Post (3.5L Early Build Ground Eyelet) (Engine) 1 Way Remote Battery Jumper Terminal: Diagrams Negative Remote Jump Post (3.5L Early Build Ground Eyelet) (Engine) 1 Way Connector (3.5L EARLY BUILD GROUND EYELET) - (ENGINE) 1 WAY POST-REMOTE JUMP-NEGATIVE (3.5L EARLY BUILD GROUND EYELET) - (ENGINE) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Diagrams > Negative Remote Jump Post (3.5L Early Build Ground Eyelet) (Engine) 1 Way > Page 5614 Remote Battery Jumper Terminal: Diagrams Negative Remote Jump Post (Battery Eyelet) (Battery) 1 Way Connector (BATTERY EYELET) - (BATTERY) 1 WAY POST-REMOTE JUMP-NEGATIVE (BATTERY EYELET) - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Diagrams > Negative Remote Jump Post (3.5L Early Build Ground Eyelet) (Engine) 1 Way > Page 5615 Remote Battery Jumper Terminal: Diagrams Negative Remote Jump Post (Except 3.5L Early Build Ground Eyelet) (Starter/Engine) 1 Way Connector (EXCEPT 3.5L EARLY BUILD GROUND EYELET) - (STARTER/ENGINE) 1 WAY POST-REMOTE JUMP-NEGATIVE (EXCEPT 3.5L EARLY BUILD GROUND EYELET) (STARTER/ENGINE) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Diagrams > Negative Remote Jump Post (3.5L Early Build Ground Eyelet) (Engine) 1 Way > Page 5616 Remote Battery Jumper Terminal: Diagrams Positive Remote Jump Post (Gas Battery Eyelet) (Battery) 1 Way Connector (GAS BATTERY EYELET) - (BATTERY) 1 WAY POST-REMOTE JUMP-POSITIVE (GAS BATTERY EYELET) - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications GENERATOR Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Generator (Gas) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Generator (Gas) > Page 5623 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Generator (Gas Eyelet) (Engine) 1 Way Alternator: Diagrams Generator (Gas Eyelet) (Engine) 1 Way Connector (GAS EYELET) - (ENGINE) 1 WAY GENERATOR (GAS EYELET) - (ENGINE) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Generator (Gas Eyelet) (Engine) 1 Way > Page 5626 Alternator: Diagrams Generator (Gas) 2 Way Connector (GAS) - (ENGINE) 2 WAY GENERATOR (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Generator - Description Alternator: Description and Operation Generator - Description DESCRIPTION The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Generator - Description > Page 5629 Alternator: Description and Operation Generator - Operation OPERATION As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. The Y type stator winding connections deliver the induced AC current to positive and negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: - Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode - Damaged internal fins Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal Alternator: Service and Repair Generator - Removal 3.5L CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. 1. Disconnect and isolate negative battery cable. 2. Remove generator drive belt, See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 3. Unsnap plastic protective cover (4) from B+ mounting stud. 4. Remove B+ terminal mounting nut (3) and B+ terminal (2) at top of generator. 5. Disconnect field wire electrical connector (1) by pushing on connector tab. 6. Remove short mounting bolt (3) from generator (1). 7. Remove long mounting bolt (2) from generator (1). 8. Remove generator (1) from engine mounting bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 5632 Alternator: Service and Repair Generator - Installation 3.5L 1. Install generator (1) to engine mounting bracket. 2. Install long mounting bolt (2) and short mounting bolt (3) to generator (1). Tighten bolts to 42 Nm (31 ft. lbs.). 3. Connect field wire connector (1) into generator. 4. Install B+ terminal (2) and nut (3) to generator mounting stud. Tighten nut to 10 Nm (88.5 in. lbs.) 5. Snap plastic protective cover (4) to B+ terminal. 6. Install drive belt Refer to Cooling System for belt routing, belt adjustment and bolt tightening procedures. 7. Connect negative battery cable, tighten nut to 4.5 Nm (40 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations Ignition Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations > Page 5637 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Ignition Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 Ignition Switch: Connector Views Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN) (1). The WIN and the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch (5) located on the face of the instrument panel just to the inboard side of the steering column. The WIN housing is constructed of molded black plastic and it includes four integral mounting bosses (4), which are secured to the instrument panel structure with screws. Two connector receptacles are integral to the back of the switch housing. One (3) connects the WIN to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The other (2) is a dedicated connector for the coaxial cable input from the optional remote start system external antenna module. The WIN is an integrated electronic receiver that replaces the ignition switch. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) communication. It also communicates with the TPM trigger transponders (if equipped) and steering column lock module (if equipped) using a Local Interface Network (LIN) data bus connection. The WIN provides a switched 12-volt source through an isolated switch for the steering column lock module required for certain export market vehicles. It also contains a key removal inhibit solenoid, an electronic Brake Transmission Shift Interlock (BTSI) solenoid, a key-in warning contact and it serves as the real time vehicle clock by transmitting the clock information to other electronic modules over the CAN data bus. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged, the entire WIN must be replaced. When replacing the WIN, you must also replace the steering column lock module (if equipped). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 5657 Ignition Switch: Description and Operation Wireless Ignition Node Receiver - Operation OPERATION Following are brief descriptions of the systems that the WIN controls. IGNITION SWITCH The Wireless Ignition Node (WIN) incorporates an integral ignition switch that consists of four rotary positions with three detent positions and one spring-loaded position. The one extreme clockwise position is a spring-loaded momentary contact "START" position. When released from the "START" position, the switch will automatically return to the detent "ON" position. The other position includes a detent "ACCESSORY" position and a detent "LOCK" position. The WIN reads the position of the ignition switch and transmits the data via the CAN data bus. These positions include "LOCK" with ignition key-out, "LOCK" with ignition key-in, "ACCESSORY,""RUN," and "START." SENTRY KEY IMMOBILIZER SYSTEM (SKIS) Upon failure of proper Sentry Key Immobilizer (SKIS) communication to the Powertrain Control Module, (PCM), the PCM will not allow the vehicle to crank. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Operation. REMOTE KEYLESS ENTRY (RKE) The Remote Keyless Entry (RKE), transmitter uses Radio Frequency (RF) signals to communicate with the WIN, and the WIN relays the RKE requests to other modules in the vehicle over the CAN data bus. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Operation TIRE PRESSURE MONITORING (TPM) The Tire Pressure Monitoring (TPM) system uses radio and sensor technology to monitor tire air pressure levels. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Operation. REMOTE START WITH/EXTENDED RANGE ANTENNA Further information concerning the Remote Start System. See: Keyless Starting System/Description and Operation/Starting System - Operation BRAKE TRANSMISSION SHIFTER INTERLOCK (BTSI) The Brake Transmission Shifter/Ignition Interlock (BTSI) is controlled by the WIN. The BTSI prevents the transmission gear shifter from being moved out of PARK without a driver in place. PARK SHIFT INTERLOCK The key removal inhibit solenoid internal to the WIN prevents the FOB with Integrated KEY (FOBIK) from being rotated in the ignition switch to the LOCK position for all vehicles with an automatic transmission unless the transmission shift lever is in the PARK position. The WIN module monitors a hard wired input from a switch integral to the automatic transmission shifter module to control this feature. The key removal inhibit solenoid is electronically disabled internally by the WIN on vehicles with a manual transmission. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Wireless Ignition Node Receiver - Description > Page 5658 Ignition Switch: Description and Operation Ignition Switch - Description DESCRIPTION This vehicle is equipped with a Wireless Ignition Node (WIN). The WIN, along with the FOB with Integrated Key (FOBIK) are the primary components of the keyless ignition system. The only visible component of the WIN is the ignition switch located on the face of the instrument panel just to the inboard side of the steering column. The remainder of the WIN including its mounting provisions and electrical connections are concealed within the instrument panel. In addition to replacing a conventional keyed ignition switch, the WIN is an integrated electronic receiver that serves as the base station in the vehicle. It communicates with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The WIN interfaces with the Remote Keyless Entry (RKE) FOBIK and the Tire Pressure Monitor (TPM) sensors (if equipped) using Radio Frequency (RF) communication, with the Sentry Key Immobilizer System (SKIS) transponder within the FOBIK using Low Frequency (LF) RF communication. The WIN cannot be adjusted or repaired, but is flash update capable. If ineffective or damaged the entire WIN must be replaced See: Service and Repair/Wireless Ignition Node Receiver - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Ignition Switch: Symptom Related Diagnostic Procedures FOBIK TRAPPED IN WIN The Fob with Integrated Key (FOBIK) cannot be rotated to the LOCK position, allowing it to be removed from the ignition switch also referred to as the Wireless Ignition Node/WIN. The automatic transmission or transaxle is shifted mechanically through a cable from the gearshift lever mechanism to the transmission or transaxle valve body. A gated park switch is physically located on and integral to the gearshift lever mechanism and is hard wired directly to the WIN. The gated park switch is a simple plunger-like actuated open or closed contact switch that could be considered redundant to the Transmission Range Sensor (TRS) except that it monitors the position selected with the gearshift lever, while the TRS monitors the position or gear of the transmission or transaxle that is actually engaged. A damaged or improperly adjusted gearshift cable could result in a different gear being engaged than that which is selected. The WIN uses the gated park switch input to control an internal key lock solenoid, which controls whether the FOBIK can be rotated to the LOCK position. When the gearshift lever is not in the PARK position, the gated park switch is a closed circuit, the key lock solenoid is energized and the FOBIK cannot be rotated to the LOCK position for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 4. Remove the instrument cluster bezel, reposition the instrument, and remove the upper WIN bracket attaching screw (1). See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 5. Disconnect the WIN electrical connector (1) and the antenna connector (3) from the WIN. 6. Utilize a trim stick or equivalent and gently pry WIN trim ring (2) away from the instrument panel. 7. Remove the lower WIN attaching screw (5). 8. Remove the lower WIN bracket attaching screw (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 5663 9. Rotate the WIN (1) and (2) bracket to assist in removal from the instrument panel. 10. Remove the WIN from the instrument panel opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 5664 Ignition Switch: Service and Repair Wireless Ignition Node Receiver - Installation INSTALLATION NOTE: The WIN initialization procedure is required whenever the WIN or shaft lock module is replaced on vehicles equipped with the shaft lock module. 1. Rotate and position the WIN (1) and bracket (2) into the to instrument panel opening. 2. Install the lower WIN bracket attaching screw (4). 3. Install the lower WIN attaching screw (5). 4. Connect the WIN electrical connector (1) and antenna connector (3) to the WIN. 5. Install the WIN trim ring (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair > Wireless Ignition Node Receiver - Removal > Page 5665 6. Install the upper WIN bracket attaching screw (1) and reposition the instrument cluster into the instrument panel and install the instrument cluster bezel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install upper steering column shroud. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Install knee blocker. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker Installation. 9. Connect negative battery cable. 10. If necessary, program the WIN, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description Keyless Start Antenna: Description and Operation Remote Start Antenna - Description DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the Wireless Ignition Node (WIN) (1), a length of coaxial cable (2), two mounting clips (3 and 4) and a control module/antenna (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description > Page 5671 Keyless Start Antenna: Description and Operation Remote Start Antenna - Operation OPERATION The remote start antenna is an external hidden antenna located at the driver's side front of dash. The antenna interfaces with the Wireless Integration Node (WIN) through a coaxial electrical cable and electrical connector. The antenna helps to amplify the signal for the Remote Keyless Entry (RKE) key fob. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. Failure to do this may result in serious or fatal injury. The remote start antenna is located driver's side front of dash. 1. Disconnect and isolate the battery negative cable. 2. Remove radio. Refer to See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 3. Remove instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 4. Remove the instrument panel top pad. Refer to See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. NOTE: During removal of the remote start antenna note the routing location of the coaxial cable. 5. Disconnect remote start antenna coaxial cable connector (1) from skreem module (3). 6. Remove the mounting clip (2). 7. Remove the mounting clip at the steering column reinforcement bracket. 8. Remove screws (1) and remove remote start antenna (2) from instrument panel assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 5674 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION NOTE: Make sure the remote start antenna is positioned the same way noted during the removal procedure. 1. Install the remote start antenna (2) and screws (1) to instrument panel assembly. Tighten to 2.5 Nm (22 in. lbs.). 2. Route the remote start coaxial cable in the position noted during the removal procedure. 3. Install the coaxial cable mounting clip at the steering column reinforcement bracket. 4. Install the mounting clip (2). 5. Connect remote start antenna coaxial cable connector (1) to skreem module (3). 6. Install instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install radio. Refer to See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 8. Install the instrument panel top pad. Refer to See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. 9. Connect negative battery cable. Tighten to 5 Nm (45 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5678 Neutral Safety Switch: Diagrams Connector (MTX) - (BODY) 3 WAY SWITCH-CLUTCH INTERLOCK (MTX) - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications Starter Motor: Specifications STARTER MOTOR Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5682 Starter Motor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5683 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5684 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (2.7L/3.5L) (Engine) 1 Way Starter Motor: Diagrams Starter (2.7L/3.5L) (Engine) 1 Way Connector (2.7L/3.5L) - (ENGINE) 1 WAY STARTER (2.7L/3.5L) - (ENGINE) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (2.7L/3.5L) (Engine) 1 Way > Page 5687 Starter Motor: Diagrams Starter (3.5L) (Engine) 1 Way Connector (3.5L) - (ENGINE) 1 WAY STARTER (3.5L) - (ENGINE) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal Starter Motor: Service and Repair Starter - Removal 3.5L 1. Disconnect and isolate negative battery cable. 2. Remove heat shield nuts (1), (3) and position heat shield (2) aside. 3. Remove belly pan, if equipped. 4. Remove front mount through bolt (1) from transmission bracket (2) and mount (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5690 5. Remove rear bolts (1) from transmission crossmember. 6. Remove front bolts (1) from transmission crossmember. 7. Remove transmission crossmember. 8. Remove heat shield bolts (1) and remove heat shield (3). 9. Remove oxygen sensor (2) and position aside. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5691 10. Remove bolt (2) from transmission bracket (1). 11. Remove bolts (1), (3) and transmission bracket (2) from transmission housing. 12. Remove battery cable nut (1), ignition wire (2) and battery cable (3) from starter solenoid stud. 13. Disconnect electrical connector (4) from starter solenoid. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5692 14. Remove starter mounting bolts (2) and ground wire (1) and remove the starter (4) from the transmission housing (3). 15. Remove starter motor dust shield (2) from starter (1). NOTE: If the flywheel is damaged refer to the transmission section for flywheel replacement. 16. Rotate and fully inspect flywheel gears (1) and wields (2) for damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5693 Starter Motor: Service and Repair Starter - Installation 3.5L 1. Install starter motor dust shield (2) to starter (1). 2. Position starter (4) into transmission housing (3), install ground wire (1) and starter mounting bolts (2). Tighten bolts to 54 Nm (40 ft. lbs.). 3. Install battery cable (3), ignition wire (2) and battery cable nut (1) to starter solenoid stud. Tighten nut to 10 Nm (90 in. lbs.). 4. Connect electrical connector (4) to starter solenoid. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5694 5. Install transmission bracket (2) and bolts (1), (3) to transmission housing. Hand tighten bolts. 6. Install bolt (2) to transmission bracket (1). Hand tighten bolt. CAUTION: The torque reaction bracket bolts need to be tightened using a mandatory torque sequence. Failure to tighten bolts using the mandatory torque sequence provided may result in damage to the fasteners, bracket, and threaded bolts holes for the engine and transmission. 7. Tighten bolts in a mandatory torque sequence to 50 Nm (37 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5695 8. Install oxygen sensor (2) and tighten to 41 Nm (30 ft. lbs). 9. Install heat shield (3) and bolts (1). Tighten bolts to 12 Nm (106 in. lbs). 10. Install bolts (1) to transmission crossmember. Tighten bolts to 55 Nm (40.5 ft. lbs.). 11. Install bolts (1) to transmission crossmember. Tighten bolts to 50 Nm (37 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 5696 12. Install front mount through bolt (1) to transmission bracket (2) and mount (3). Tighten bolt to 47 Nm (35 ft. lbs.). 13. If equipped, install belly pan. NOTE: Make sure the lower heat shield is installed to the lower stud before the upper heat shield is install. The upper heat shield stacks on top of the lower heat shield, and both shields are held together by the lower nut. 14. Position heat shield (2) over the studs and install heat shield nuts (1), (3). Tighten nuts to 12 Nm (106 in. lbs). 15. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5700 Starter Relay: Diagrams Connector - (IN TIPM) 5 WAY RELAY-STARTER - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) Auxiliary Power Outlet: Locations AC Power Outlet (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5706 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5707 Auxiliary Power Outlet: Locations Console Power Outlet Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5708 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5709 Auxiliary Power Outlet: Locations Instrument Panel Power Outlet Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5710 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5711 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 5712 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Auxiliary Power Outlet: Connector Views AC Power Outlet (Except Export) (Rear Console) 6 Way Connector (EXCEPT EXPORT) - (REAR CONSOLE) 6 WAY POWER OUTLET-AC (EXCEPT EXPORT) - (REAR CONSOLE) 6 WAY Console Power Outlet (Rear Console) 3 Way Connector - (REAR CONSOLE) 3 WAY POWER OUTLET-CONSOLE - (REAR CONSOLE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Instrument Panel Power Outlet (Front Console) 3 Way Connector - (FRONT CONSOLE) 3 WAY POWER OUTLET-INSTRUMENT PANEL - (FRONT CONSOLE) 3 WAY Rear Power Outlet (Body) 3 Way Connector - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 POWER OUTLET-REAR - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Auxiliary Power Outlet: Electrical Diagrams HORN/CIGAR LIGHTER/POWER OUTLET - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Horn/Cigar Lighter/Power Outlet 8W-41-01 Horn/Cigar Lighter/Power Outlet 8W-41-02 (EVIC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Horn/Cigar Lighter/Power Outlet 8W-41-03 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Horn/Cigar Lighter/Power Outlet 8W-41-04 (Except Export) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 12 Volt Power Outlet - Removal Auxiliary Power Outlet: Service and Repair 12 Volt Power Outlet - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using Power Outlet Remover 9857 (4). Insert the tool with tips against bosses (1). 3. Pull out the base (3) through mounting ring by gently rocking power outlet remover. 4. Disconnect the base wires (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 12 Volt Power Outlet - Removal > Page 5738 Auxiliary Power Outlet: Service and Repair 12 Volt Power Outlet - Installation INSTALLATION 1. Connect wire harness connectors. 2. Install power outlet to instrument panel. 3. Connect battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Circuit Breaker 1 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Circuit Breaker 1 > Page 5743 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) Circuit Breaker: Diagrams Circuit Breaker 1 (In TIPM) Connector - (IN TIPM) CIRCUIT BREAKER 1 - (IN TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 5746 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 5747 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 5748 Circuit Breaker: Diagrams Power Seat Circuit Breaker (Seat) 2 Way Connector - (SEAT) 2 WAY CIRCUIT BREAKER-POWER SEAT - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module Fuse: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5753 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5754 The Totally Integrated Power Module (TIPM) is located in the engine compartment near the air cleaner assembly. This center contains fuses and relays. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5755 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5756 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5757 Fuse: Locations Fuse Locations/Types FUSES/TOTALLY INTEGRATED POWER MODULE (TIPM) TOTALLY INTEGRATED POWER MODULE (TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5758 The Totally Integrated Power Module (TIPM) is located in the engine compartment near the air cleaner assembly. This center contains fuses and relays. CAUTION: - When installing the power module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the TIPM, and possibly result in an electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Relays FUSE LOCATIONS AND TYPES Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5759 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5760 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 5761 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5762 Fuse: Application and ID Connector - (IN TIPM) CIRCUIT BREAKER 1 - (IN TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5763 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 5764 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 5767 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal Fuse: Service and Repair IOD Fuse - Removal REMOVAL NOTE: When removing or installing the Ignition Off Draw (IOD) fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Pull on IOD fuse (J13) holder until it reaches the first detent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal > Page 5770 Fuse: Service and Repair IOD Fuse - Installation INSTALLATION 1. Push on IOD fuse until completely seated. 2. Install the cover to the Totally Integrated Power Module (TIPM). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5789 Fuse Block: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5790 Fuse Block: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation Technical Service Bulletin # J09 Date: 090325 Recall - Power Inverter Connector Relocation March 2009 Dealer Service Instructions for: Safety Recall J09 Power Inverter Connector Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles NOT equipped with a 115 volt power inverter (sales code JKV) built through February 6, 2009 (MDH 020614). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The power inverter 9-way white electrical connector on about 16,800 of the above vehicles may become contaminated, potentially causing the connector to melt and/or catch fire. Repair The power inverter 9-way white electrical connector must be relocated and the 25 amp fuse for the 9-way white connector must be removed from the Totally Integrated Power Module (TIPM). Parts Information Special Tools No special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 5802 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Move the driver's seat to the full forward position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 5803 2. Working from the left rear door opening, locate the seat wiring harness where it comes through the slit in the carpet under the driver's seat (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 5804 3. Locate the taped back 9-way white connector under the carpet by accessing it through the carpet slit (Figure 2). 4. Break the tape and pull the 9-way white connector through the carpet opening toward the seat in-line connectors (Figure 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 5805 5. Using a plastic tie strap, permanently tie back the white 9-way connector approximately 2 inches (50 mm) from the back of the seat inline grey connector. CAUTION: Assure that the 9-way white connector cannot lay on the carpet. 6. Move the seat back to its original position. 7. Open the hood. 8. Locate the Totally Integrated Power Module (TIPM) in the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 5806 9. Open the cover on the TIPM and locate, remove and discard the 25 amp fuse shown in Figure 4. 10. Close the cover on the TIPM. 11. Close the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 5807 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > NHTSA09V082000 > Mar > 09 > Recall 09V082000: Power Inverter Connector Multiple Junction Connector: Recalls Recall 09V082000: Power Inverter Connector VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: March 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V082000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 16852 SUMMARY: Chrysler is recalling 16,852 M/Y 2009 Dodge Journey equipped without optional 115 volt auxiliary power outlet. An unused electrical connector for the optional 115 volt auxiliary power outlet option may become corroded and could short circuit. CONSEQUENCE: If the fuse for this circuit does not blow, the connector could overheat and potentially catch fire. REMEDY: Dealers will re-route and stow the 115 volt auxiliary power outlet connector and pull the 25 amp fuse to remove power from this unused circuit free of charge. The recall is expected to begin during March 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation Technical Service Bulletin # J09 Date: 090325 Recall - Power Inverter Connector Relocation March 2009 Dealer Service Instructions for: Safety Recall J09 Power Inverter Connector Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles NOT equipped with a 115 volt power inverter (sales code JKV) built through February 6, 2009 (MDH 020614). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The power inverter 9-way white electrical connector on about 16,800 of the above vehicles may become contaminated, potentially causing the connector to melt and/or catch fire. Repair The power inverter 9-way white electrical connector must be relocated and the 25 amp fuse for the 9-way white connector must be removed from the Totally Integrated Power Module (TIPM). Parts Information Special Tools No special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 5817 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Move the driver's seat to the full forward position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 5818 2. Working from the left rear door opening, locate the seat wiring harness where it comes through the slit in the carpet under the driver's seat (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 5819 3. Locate the taped back 9-way white connector under the carpet by accessing it through the carpet slit (Figure 2). 4. Break the tape and pull the 9-way white connector through the carpet opening toward the seat in-line connectors (Figure 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 5820 5. Using a plastic tie strap, permanently tie back the white 9-way connector approximately 2 inches (50 mm) from the back of the seat inline grey connector. CAUTION: Assure that the 9-way white connector cannot lay on the carpet. 6. Move the seat back to its original position. 7. Open the hood. 8. Locate the Totally Integrated Power Module (TIPM) in the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 5821 9. Open the cover on the TIPM and locate, remove and discard the 25 amp fuse shown in Figure 4. 10. Close the cover on the TIPM. 11. Close the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 5822 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > NHTSA09V082000 > Mar > 09 > Recall 09V082000: Power Inverter Connector Multiple Junction Connector: All Technical Service Bulletins Recall 09V082000: Power Inverter Connector VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: March 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V082000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 16852 SUMMARY: Chrysler is recalling 16,852 M/Y 2009 Dodge Journey equipped without optional 115 volt auxiliary power outlet. An unused electrical connector for the optional 115 volt auxiliary power outlet option may become corroded and could short circuit. CONSEQUENCE: If the fuse for this circuit does not blow, the connector could overheat and potentially catch fire. REMEDY: Dealers will re-route and stow the 115 volt auxiliary power outlet connector and pull the 25 amp fuse to remove power from this unused circuit free of charge. The recall is expected to begin during March 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 5831 Power Distribution Module: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 5832 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 5833 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5836 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5837 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5838 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5839 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5840 Power Distribution Module: Diagrams Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5841 Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5842 MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5843 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5844 Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5845 Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5846 Module-Totally Integrated Power C1 Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5847 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5848 Module-Totally Integrated Power C2 Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5849 Module-Totally Integrated Power C3 Connector C3 - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5850 MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Module-Totally Integrated Power C4 Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5851 Module-Totally Integrated Power C5 Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5852 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5853 Module-Totally Integrated Power C6 Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5854 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5855 Module-Totally Integrated Power C7 Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5856 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5857 Totally Integrated Power Module C2 (Headlamp And Dash) 26 Way Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5858 Totally Integrated Power Module C8 (Battery) 1 Way Connector C8 - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5859 MODULE-TOTALLY INTEGRATED POWER - (BATTERY) 1 WAY Totally Integrated Power Module C5 (Headlamp And Dash) 40 Way Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5860 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5861 Totally Integrated Power Module C6 (Headlamp And Dash) 40 Way Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5862 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5863 Totally Integrated Power Module C7 (Headlamp And Dash) 50 Way Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5864 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5865 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located on the right side of the engine compartment. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the TIPM mounting bracket by four clips integral to the TIPM housing. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description > Page 5868 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud with a nut. Internal connection of all the TIPM circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fuses, relays and TIPM housing assembly are available for service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5871 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Position the front drivers seat to the full rearward position. 3. Remove the power inverter (2) mounting retainers (1) located under the carpet. 4. Disconnect the electrical connectors. 5. Remove the power inverter module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5874 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Position the inverter into the vehicle and install mounting fasteners. 2. Connect the electrical connectors. 3. Connect the battery negative cable. 4. Position the front drivers seat back to the original position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5875 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Release the Totally Integrated Power Module (TIPM) cover retaining clips and open the TIPM cover. 4. Remove the TIPM positive cable retaining nut and remove the cable from the stud. 5. Depress the four mounting clips to disengage and remove the TIPM housing from its mounting bracket. 6. Disconnect each of the seven TIPM wire harness connectors. 7. Remove the TIPM from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5876 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from Dealer CONNECT 1. Position the TIPM into the engine compartment. 2. Connect each of the seven TIPM wire harness connectors. 3. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully seated. 4. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Tighten the nut to 9 - 11 Nm (80 - 100 in. lbs.). 5. Open the TIPM cover and fully seat the airbag fuse holder (two fuses in one yellow carrier) and the Ignition Off Draw (IOD) fuse. 6. Connect the battery negative cable. 7. Close the hood. 8. Insert the ignition key and turn it to the RUN position and wait twelve seconds. The TIPM will collect the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the OFF position and then back to the ON position and verify proper vehicle systems operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 5882 Power Distribution Module: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 5883 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 5884 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5887 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5888 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5889 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5890 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5891 Power Distribution Module: Diagrams Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5892 Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5893 MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5894 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5895 Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5896 Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5897 Module-Totally Integrated Power C1 Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5898 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5899 Module-Totally Integrated Power C2 Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5900 Module-Totally Integrated Power C3 Connector C3 - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5901 MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Module-Totally Integrated Power C4 Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5902 Module-Totally Integrated Power C5 Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5903 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5904 Module-Totally Integrated Power C6 Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5905 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5906 Module-Totally Integrated Power C7 Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5907 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5908 Totally Integrated Power Module C2 (Headlamp And Dash) 26 Way Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5909 Totally Integrated Power Module C8 (Battery) 1 Way Connector C8 - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5910 MODULE-TOTALLY INTEGRATED POWER - (BATTERY) 1 WAY Totally Integrated Power Module C5 (Headlamp And Dash) 40 Way Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5911 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5912 Totally Integrated Power Module C6 (Headlamp And Dash) 40 Way Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5913 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5914 Totally Integrated Power Module C7 (Headlamp And Dash) 50 Way Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5915 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 5916 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located on the right side of the engine compartment. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the TIPM mounting bracket by four clips integral to the TIPM housing. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description > Page 5919 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud with a nut. Internal connection of all the TIPM circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fuses, relays and TIPM housing assembly are available for service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5922 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Position the front drivers seat to the full rearward position. 3. Remove the power inverter (2) mounting retainers (1) located under the carpet. 4. Disconnect the electrical connectors. 5. Remove the power inverter module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal > Page 5925 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Position the inverter into the vehicle and install mounting fasteners. 2. Connect the electrical connectors. 3. Connect the battery negative cable. 4. Position the front drivers seat back to the original position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal > Page 5926 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Release the Totally Integrated Power Module (TIPM) cover retaining clips and open the TIPM cover. 4. Remove the TIPM positive cable retaining nut and remove the cable from the stud. 5. Depress the four mounting clips to disengage and remove the TIPM housing from its mounting bracket. 6. Disconnect each of the seven TIPM wire harness connectors. 7. Remove the TIPM from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal > Page 5927 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from Dealer CONNECT 1. Position the TIPM into the engine compartment. 2. Connect each of the seven TIPM wire harness connectors. 3. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully seated. 4. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Tighten the nut to 9 - 11 Nm (80 - 100 in. lbs.). 5. Open the TIPM cover and fully seat the airbag fuse holder (two fuses in one yellow carrier) and the Ignition Off Draw (IOD) fuse. 6. Connect the battery negative cable. 7. Close the hood. 8. Insert the ignition key and turn it to the RUN position and wait twelve seconds. The TIPM will collect the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the OFF position and then back to the ON position and verify proper vehicle systems operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 5932 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 5933 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way Relay Box: Diagrams Run Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 5936 Relay Box: Diagrams Run/Accessory Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/ACCESSORY - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 5937 Relay Box: Diagrams Run/Start Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/START - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5938 Relay Box: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5939 Relay Box: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 5944 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 5945 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way Relay Box: Diagrams Run Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 5948 Relay Box: Diagrams Run/Accessory Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/ACCESSORY - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 5949 Relay Box: Diagrams Run/Start Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/START - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5950 Relay Box: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5951 Relay Box: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement Technical Service Bulletin # K07 Date: 110218 Recall - Front Door Wiring Harness Replacement February 2011 Dealer Service Instructions for: Safety Recall K07 Front Door Wiring Harnesses Safety Recall K07 Front Door Wiring Harnesses Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from November 01, 2007 through November 07, 2008 (MDH 110122 through 110723). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front door wiring harnesses on about 65,000 of the above vehicles may fatigue and break. Broken wires could interrupt the circuits for the side impact sensor(s) located inside the front doors. This could resulting in the illumination of the airbag warning lamp and loss of side crash sensing capability. Repair The right and left front door wiring harnesses must be replaced. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 5960 These special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 5961 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Open the hood. 2. Roll down both front door windows. 3. Disconnect and isolate the negative battery cable at the left shock tower. 4. Remove the front door window switch, grab handle cup, and release handle bezel (Figure 1). 5. Remove the front door panel (Figure 1). 6. Remove the front door inner window seal (Figure 1). 7. Separate the oval wiring harness grommet from the lower "A" pillar (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 5962 8. Disconnect the body electrical connectors from the front door wiring harness (Figure 2). 9. Remove the two door grommet retaining screws (Figure 2). 10. Remove the door speaker from the door and disconnect the electrical connector (Figure 2). 11. Open the access door and disconnect the door latch electrical connector (Figure 3). 12. Disconnect the remaining electrical connectors and remove the front door wiring harness from the vehicle (Figure 2). CAUTION: Note the wiring harness routing before removing the wiring harness from the door. The new wiring harness must be routed in the same location as the original wiring harness. 13. Place the new front door wiring harness into position on the door. 14. Connect the front door wiring harness connectors to the body electrical connectors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 5963 15. Snap the oval wiring harness grommet into the oval hole on the "A" pillar (Figure 1). 16. Place the door grommet into position and install the two retaining screws (Figure 1). 17. Connect the remaining electrical connectors to their respective modules/connectors (Figure 2). 18. Connect the door latch electrical connector and close the access door (Figure 3). 19. Connect the door speaker electrical connector and install the door speaker (Figure 4). 20. Install the front door inner window seal. 21. Install the front door panel. 22. Install the front door window switch, grab handle cup, and release handle bezel. 23. Repeat steps 4 through 22 on the other front door. 24. Connect the negative battery cable. 25. Using Mopar Total Clean or equivalent, clean both front door panels 26. On vehicles equipped with Express Window Up/Down (sales code JSC), perform Steps 27 through 30. 27. Connect the wiTECH to the vehicle. 28. Clear all Diagnostic Trouble Codes (DTC's). 29. Clear/Denormalize the door modules using the following procedures: a. Click on the "Miscellaneous Functions" tab. b. Select "Denormalize Window/Reset ECU" and follow the directions to clear/denormalize the door module memory. 30. Relearn/Normalize the door modules using the following procedure: a. Place the vehicle on a battery charger or have the engine running. b. Raise the front door glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the front door glass is fully closed. Continue to hold the window switch up for three seconds after the front door glass is fully closed. c. Lower the front door glass to the full-down position by pushing down (depress) the window switch to its second detent and hold the switch until the front door glass is fully open. Continue to hold the window switch down for three seconds after the front door glass is fully open. d. Check the operation of the express-up and express-down features. If the express-up feature does not work, repeat the procedure starting with Step 30b. e. Check that the front door glass reverses when in the express-up mode by holding a pen in the path of the glass. f. Repeat steps 30b. through 30e. on the other front door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 5964 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA10V658000 > Dec > 10 > Recall 10V658000: Front Door Wiring Harnesses Wiring Harness: Recalls Recall 10V658000: Front Door Wiring Harnesses VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler Group LLC. MFR'S REPORT DATE: December 23, 2010 NHTSA CAMPAIGN ID NUMBER: 10V658000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System: Wiring POTENTIAL NUMBER OF UNITS AFFECTED: 65,180 SUMMARY: Chrysler is recalling certain model year 2009 Dodge Journey vehicles manufacturer from November 1, 2007, through September 7, 2008. The wires within the front door wire harnesses may fatigue and break, which can interrupt the circuits for the side impact sensor(s), resulting in an airbag warning lamp illumination and loss of side crash sensing capability. CONSEQUENCE: In the event of a crash, the side airbag may not deploy, reducing the protection intended for the occupant and increasing the risk of injuries. REMEDY: Chrysler will notify owners and replace the left and right door wiring harnesses free of charge. The safety recall is expected to begin during February 2011. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler safety recall No. K07. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing Technical Service Bulletin # H21 Date: 080701 Recall - Engine Wire Harness Routing July 2008 Dealer Service Instructions for: Safety Recall H21 Engine Wiring Harness Routing Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) # 08-040 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles equipped with a 3.5L engine ("V" in the 8th VIN Position) built from February 5, 2008 through March 14, 2008 (MDH 020506 through 031423). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine wiring harness on about 5,900 of the above vehicles may chafe on the left transaxle mount. This could cause a short circuit and result in an engine compartment fire. Repair The engine wiring harness must be inspected for damage, repaired if necessary and rerouted away from the left transaxle mount. Parts Information Due to the likelihood that the required plastic tie straps are already in your parts inventory, no plastic tie straps will be distributed initially. The following plastic tie strap is available as required. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 5973 All dealers will receive one copy of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Disconnect the negative battery connection on the left shock tower. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 5974 2. Inspect the engine wiring harness and, if equipped, the 120 volt engine block heater cord at the left transaxle mount for chafed wires (Figure 1): > If wire chafing is not found, continue with Step 6 of this procedure. > If wire chafing is found, continue with Step 3 of this procedure. 3. Remove the wiring harness protective tape from around the damaged area. 4. Repair wire(s) as required. 5. Install electrical tape around repaired area of wiring harness. 6. Disconnect the 14-way connector using the following procedure: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 5975 a. Slide the red lock tab located on the top of the connector rearward (Figure 2). b. Push down on the black connector release tab. c. While pushing down on the black connector release tab pull the connector apart. 7. Wrap the harness side of the 14-way connector under and around the main wiring harness and reconnect the 14-way connector (Figure 3). Route the 120 volt engine block heater cord in the same manner, away from the left transaxle mount. CAUTION: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 5976 Ensure that all wiring is routed away from all sharp edges. 8. Slide the red locking tab forward to lock the 14-way connector. 9. Connect the negative battery connection on the left shock tower. 10. Reposition the main wiring harness and, if equipped, the engine block heater cord. Secure them using a tie strap as shown in Figure 4. 11. Verify that the main wiring harness and, if equipped, the engine block heater cord do not touch the left transaxle mount or any other sharp edges. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 5977 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall Front Door Wiring Harness Replacement Technical Service Bulletin # K07 Date: 110218 Recall - Front Door Wiring Harness Replacement February 2011 Dealer Service Instructions for: Safety Recall K07 Front Door Wiring Harnesses Safety Recall K07 Front Door Wiring Harnesses Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from November 01, 2007 through November 07, 2008 (MDH 110122 through 110723). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front door wiring harnesses on about 65,000 of the above vehicles may fatigue and break. Broken wires could interrupt the circuits for the side impact sensor(s) located inside the front doors. This could resulting in the illumination of the airbag warning lamp and loss of side crash sensing capability. Repair The right and left front door wiring harnesses must be replaced. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall Front Door Wiring Harness Replacement > Page 5983 These special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall Front Door Wiring Harness Replacement > Page 5984 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Open the hood. 2. Roll down both front door windows. 3. Disconnect and isolate the negative battery cable at the left shock tower. 4. Remove the front door window switch, grab handle cup, and release handle bezel (Figure 1). 5. Remove the front door panel (Figure 1). 6. Remove the front door inner window seal (Figure 1). 7. Separate the oval wiring harness grommet from the lower "A" pillar (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall Front Door Wiring Harness Replacement > Page 5985 8. Disconnect the body electrical connectors from the front door wiring harness (Figure 2). 9. Remove the two door grommet retaining screws (Figure 2). 10. Remove the door speaker from the door and disconnect the electrical connector (Figure 2). 11. Open the access door and disconnect the door latch electrical connector (Figure 3). 12. Disconnect the remaining electrical connectors and remove the front door wiring harness from the vehicle (Figure 2). CAUTION: Note the wiring harness routing before removing the wiring harness from the door. The new wiring harness must be routed in the same location as the original wiring harness. 13. Place the new front door wiring harness into position on the door. 14. Connect the front door wiring harness connectors to the body electrical connectors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall Front Door Wiring Harness Replacement > Page 5986 15. Snap the oval wiring harness grommet into the oval hole on the "A" pillar (Figure 1). 16. Place the door grommet into position and install the two retaining screws (Figure 1). 17. Connect the remaining electrical connectors to their respective modules/connectors (Figure 2). 18. Connect the door latch electrical connector and close the access door (Figure 3). 19. Connect the door speaker electrical connector and install the door speaker (Figure 4). 20. Install the front door inner window seal. 21. Install the front door panel. 22. Install the front door window switch, grab handle cup, and release handle bezel. 23. Repeat steps 4 through 22 on the other front door. 24. Connect the negative battery cable. 25. Using Mopar Total Clean or equivalent, clean both front door panels 26. On vehicles equipped with Express Window Up/Down (sales code JSC), perform Steps 27 through 30. 27. Connect the wiTECH to the vehicle. 28. Clear all Diagnostic Trouble Codes (DTC's). 29. Clear/Denormalize the door modules using the following procedures: a. Click on the "Miscellaneous Functions" tab. b. Select "Denormalize Window/Reset ECU" and follow the directions to clear/denormalize the door module memory. 30. Relearn/Normalize the door modules using the following procedure: a. Place the vehicle on a battery charger or have the engine running. b. Raise the front door glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the front door glass is fully closed. Continue to hold the window switch up for three seconds after the front door glass is fully closed. c. Lower the front door glass to the full-down position by pushing down (depress) the window switch to its second detent and hold the switch until the front door glass is fully open. Continue to hold the window switch down for three seconds after the front door glass is fully open. d. Check the operation of the express-up and express-down features. If the express-up feature does not work, repeat the procedure starting with Step 30b. e. Check that the front door glass reverses when in the express-up mode by holding a pen in the path of the glass. f. Repeat steps 30b. through 30e. on the other front door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall Front Door Wiring Harness Replacement > Page 5987 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA10V658000 > Dec > 10 > Recall 10V658000: Front Door Wiring Harnesses Wiring Harness: All Technical Service Bulletins Recall 10V658000: Front Door Wiring Harnesses VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler Group LLC. MFR'S REPORT DATE: December 23, 2010 NHTSA CAMPAIGN ID NUMBER: 10V658000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System: Wiring POTENTIAL NUMBER OF UNITS AFFECTED: 65,180 SUMMARY: Chrysler is recalling certain model year 2009 Dodge Journey vehicles manufacturer from November 1, 2007, through September 7, 2008. The wires within the front door wire harnesses may fatigue and break, which can interrupt the circuits for the side impact sensor(s), resulting in an airbag warning lamp illumination and loss of side crash sensing capability. CONSEQUENCE: In the event of a crash, the side airbag may not deploy, reducing the protection intended for the occupant and increasing the risk of injuries. REMEDY: Chrysler will notify owners and replace the left and right door wiring harnesses free of charge. The safety recall is expected to begin during February 2011. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler safety recall No. K07. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall Engine Wire Harness Routing Technical Service Bulletin # H21 Date: 080701 Recall - Engine Wire Harness Routing July 2008 Dealer Service Instructions for: Safety Recall H21 Engine Wiring Harness Routing Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) # 08-040 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles equipped with a 3.5L engine ("V" in the 8th VIN Position) built from February 5, 2008 through March 14, 2008 (MDH 020506 through 031423). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine wiring harness on about 5,900 of the above vehicles may chafe on the left transaxle mount. This could cause a short circuit and result in an engine compartment fire. Repair The engine wiring harness must be inspected for damage, repaired if necessary and rerouted away from the left transaxle mount. Parts Information Due to the likelihood that the required plastic tie straps are already in your parts inventory, no plastic tie straps will be distributed initially. The following plastic tie strap is available as required. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall Engine Wire Harness Routing > Page 5996 All dealers will receive one copy of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Disconnect the negative battery connection on the left shock tower. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall Engine Wire Harness Routing > Page 5997 2. Inspect the engine wiring harness and, if equipped, the 120 volt engine block heater cord at the left transaxle mount for chafed wires (Figure 1): > If wire chafing is not found, continue with Step 6 of this procedure. > If wire chafing is found, continue with Step 3 of this procedure. 3. Remove the wiring harness protective tape from around the damaged area. 4. Repair wire(s) as required. 5. Install electrical tape around repaired area of wiring harness. 6. Disconnect the 14-way connector using the following procedure: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall Engine Wire Harness Routing > Page 5998 a. Slide the red lock tab located on the top of the connector rearward (Figure 2). b. Push down on the black connector release tab. c. While pushing down on the black connector release tab pull the connector apart. 7. Wrap the harness side of the 14-way connector under and around the main wiring harness and reconnect the 14-way connector (Figure 3). Route the 120 volt engine block heater cord in the same manner, away from the left transaxle mount. CAUTION: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall Engine Wire Harness Routing > Page 5999 Ensure that all wiring is routed away from all sharp edges. 8. Slide the red locking tab forward to lock the 14-way connector. 9. Connect the negative battery connection on the left shock tower. 10. Reposition the main wiring harness and, if equipped, the engine block heater cord. Secure them using a tie strap as shown in Figure 4. 11. Verify that the main wiring harness and, if equipped, the engine block heater cord do not touch the left transaxle mount or any other sharp edges. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall Engine Wire Harness Routing > Page 6000 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Page 6001 Wiring Harness: Service and Repair GROMMET - A PILLAR 1. Peel the A Pillar grommet (1) off of the connector/retainer and move it up the wire harness. 2. Grasp the wire harness (2) by the convolute section of the grommet and gently pull the wire harness down towards the floor to expose the connector lock tabs. CAUTION: Do not force the locking tab past the connector body, as damage to the connector may occur. 3. While still pulling down on the harness, use a small slotted screw driver (3) to gently push one of the top lock tabs until the lock feature is flush with the connector/retainer body. 4. Repeat the step 3 for the remaining top lock tab. 5. The connector should now be able to rock out of the sheet metal hole without causing any damage to the connector or sheet metal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) Auxiliary Power Outlet: Locations AC Power Outlet (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6007 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6008 Auxiliary Power Outlet: Locations Console Power Outlet Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6009 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6010 Auxiliary Power Outlet: Locations Instrument Panel Power Outlet Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6011 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6012 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet (Except Export) > Page 6013 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Auxiliary Power Outlet: Connector Views AC Power Outlet (Except Export) (Rear Console) 6 Way Connector (EXCEPT EXPORT) - (REAR CONSOLE) 6 WAY POWER OUTLET-AC (EXCEPT EXPORT) - (REAR CONSOLE) 6 WAY Console Power Outlet (Rear Console) 3 Way Connector - (REAR CONSOLE) 3 WAY POWER OUTLET-CONSOLE - (REAR CONSOLE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Instrument Panel Power Outlet (Front Console) 3 Way Connector - (FRONT CONSOLE) 3 WAY POWER OUTLET-INSTRUMENT PANEL - (FRONT CONSOLE) 3 WAY Rear Power Outlet (Body) 3 Way Connector - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 POWER OUTLET-REAR - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Auxiliary Power Outlet: Electrical Diagrams HORN/CIGAR LIGHTER/POWER OUTLET - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Horn/Cigar Lighter/Power Outlet 8W-41-01 Horn/Cigar Lighter/Power Outlet 8W-41-02 (EVIC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Horn/Cigar Lighter/Power Outlet 8W-41-03 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Horn/Cigar Lighter/Power Outlet 8W-41-04 (Except Export) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 12 Volt Power Outlet - Removal Auxiliary Power Outlet: Service and Repair 12 Volt Power Outlet - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using Power Outlet Remover 9857 (4). Insert the tool with tips against bosses (1). 3. Pull out the base (3) through mounting ring by gently rocking power outlet remover. 4. Disconnect the base wires (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 12 Volt Power Outlet - Removal > Page 6039 Auxiliary Power Outlet: Service and Repair 12 Volt Power Outlet - Installation INSTALLATION 1. Connect wire harness connectors. 2. Install power outlet to instrument panel. 3. Connect battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Circuit Breaker 1 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Circuit Breaker 1 > Page 6044 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) Circuit Breaker: Diagrams Circuit Breaker 1 (In TIPM) Connector - (IN TIPM) CIRCUIT BREAKER 1 - (IN TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 6047 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 6048 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Circuit Breaker 1 (In TIPM) > Page 6049 Circuit Breaker: Diagrams Power Seat Circuit Breaker (Seat) 2 Way Connector - (SEAT) 2 WAY CIRCUIT BREAKER-POWER SEAT - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module Fuse: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6054 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6055 The Totally Integrated Power Module (TIPM) is located in the engine compartment near the air cleaner assembly. This center contains fuses and relays. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6056 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6057 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6058 Fuse: Locations Fuse Locations/Types FUSES/TOTALLY INTEGRATED POWER MODULE (TIPM) TOTALLY INTEGRATED POWER MODULE (TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6059 The Totally Integrated Power Module (TIPM) is located in the engine compartment near the air cleaner assembly. This center contains fuses and relays. CAUTION: - When installing the power module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the TIPM, and possibly result in an electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Relays FUSE LOCATIONS AND TYPES Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6060 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6061 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Totally Integrated Power Module > Page 6062 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 6063 Fuse: Application and ID Connector - (IN TIPM) CIRCUIT BREAKER 1 - (IN TIPM) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 6064 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 6065 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 6068 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal Fuse: Service and Repair IOD Fuse - Removal REMOVAL NOTE: When removing or installing the Ignition Off Draw (IOD) fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Pull on IOD fuse (J13) holder until it reaches the first detent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal > Page 6071 Fuse: Service and Repair IOD Fuse - Installation INSTALLATION 1. Push on IOD fuse until completely seated. 2. Install the cover to the Totally Integrated Power Module (TIPM). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6090 Fuse Block: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6091 Fuse Block: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation Technical Service Bulletin # J09 Date: 090325 Recall - Power Inverter Connector Relocation March 2009 Dealer Service Instructions for: Safety Recall J09 Power Inverter Connector Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles NOT equipped with a 115 volt power inverter (sales code JKV) built through February 6, 2009 (MDH 020614). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The power inverter 9-way white electrical connector on about 16,800 of the above vehicles may become contaminated, potentially causing the connector to melt and/or catch fire. Repair The power inverter 9-way white electrical connector must be relocated and the 25 amp fuse for the 9-way white connector must be removed from the Totally Integrated Power Module (TIPM). Parts Information Special Tools No special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 6103 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Move the driver's seat to the full forward position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 6104 2. Working from the left rear door opening, locate the seat wiring harness where it comes through the slit in the carpet under the driver's seat (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 6105 3. Locate the taped back 9-way white connector under the carpet by accessing it through the carpet slit (Figure 2). 4. Break the tape and pull the 9-way white connector through the carpet opening toward the seat in-line connectors (Figure 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 6106 5. Using a plastic tie strap, permanently tie back the white 9-way connector approximately 2 inches (50 mm) from the back of the seat inline grey connector. CAUTION: Assure that the 9-way white connector cannot lay on the carpet. 6. Move the seat back to its original position. 7. Open the hood. 8. Locate the Totally Integrated Power Module (TIPM) in the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 6107 9. Open the cover on the TIPM and locate, remove and discard the 25 amp fuse shown in Figure 4. 10. Close the cover on the TIPM. 11. Close the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 6108 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > NHTSA09V082000 > Mar > 09 > Recall 09V082000: Power Inverter Connector Multiple Junction Connector: Recalls Recall 09V082000: Power Inverter Connector VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: March 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V082000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 16852 SUMMARY: Chrysler is recalling 16,852 M/Y 2009 Dodge Journey equipped without optional 115 volt auxiliary power outlet. An unused electrical connector for the optional 115 volt auxiliary power outlet option may become corroded and could short circuit. CONSEQUENCE: If the fuse for this circuit does not blow, the connector could overheat and potentially catch fire. REMEDY: Dealers will re-route and stow the 115 volt auxiliary power outlet connector and pull the 25 amp fuse to remove power from this unused circuit free of charge. The recall is expected to begin during March 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation Technical Service Bulletin # J09 Date: 090325 Recall - Power Inverter Connector Relocation March 2009 Dealer Service Instructions for: Safety Recall J09 Power Inverter Connector Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles NOT equipped with a 115 volt power inverter (sales code JKV) built through February 6, 2009 (MDH 020614). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The power inverter 9-way white electrical connector on about 16,800 of the above vehicles may become contaminated, potentially causing the connector to melt and/or catch fire. Repair The power inverter 9-way white electrical connector must be relocated and the 25 amp fuse for the 9-way white connector must be removed from the Totally Integrated Power Module (TIPM). Parts Information Special Tools No special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 6118 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Move the driver's seat to the full forward position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 6119 2. Working from the left rear door opening, locate the seat wiring harness where it comes through the slit in the carpet under the driver's seat (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 6120 3. Locate the taped back 9-way white connector under the carpet by accessing it through the carpet slit (Figure 2). 4. Break the tape and pull the 9-way white connector through the carpet opening toward the seat in-line connectors (Figure 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 6121 5. Using a plastic tie strap, permanently tie back the white 9-way connector approximately 2 inches (50 mm) from the back of the seat inline grey connector. CAUTION: Assure that the 9-way white connector cannot lay on the carpet. 6. Move the seat back to its original position. 7. Open the hood. 8. Locate the Totally Integrated Power Module (TIPM) in the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 6122 9. Open the cover on the TIPM and locate, remove and discard the 25 amp fuse shown in Figure 4. 10. Close the cover on the TIPM. 11. Close the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 6123 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > NHTSA09V082000 > Mar > 09 > Recall 09V082000: Power Inverter Connector Multiple Junction Connector: All Technical Service Bulletins Recall 09V082000: Power Inverter Connector VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: March 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V082000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 16852 SUMMARY: Chrysler is recalling 16,852 M/Y 2009 Dodge Journey equipped without optional 115 volt auxiliary power outlet. An unused electrical connector for the optional 115 volt auxiliary power outlet option may become corroded and could short circuit. CONSEQUENCE: If the fuse for this circuit does not blow, the connector could overheat and potentially catch fire. REMEDY: Dealers will re-route and stow the 115 volt auxiliary power outlet connector and pull the 25 amp fuse to remove power from this unused circuit free of charge. The recall is expected to begin during March 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 6132 Power Distribution Module: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 6133 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 6134 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6137 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6138 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6139 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6140 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6141 Power Distribution Module: Diagrams Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6142 Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6143 MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6144 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6145 Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6146 Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6147 Module-Totally Integrated Power C1 Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6148 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6149 Module-Totally Integrated Power C2 Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6150 Module-Totally Integrated Power C3 Connector C3 - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6151 MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Module-Totally Integrated Power C4 Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6152 Module-Totally Integrated Power C5 Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6153 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6154 Module-Totally Integrated Power C6 Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6155 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6156 Module-Totally Integrated Power C7 Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6157 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6158 Totally Integrated Power Module C2 (Headlamp And Dash) 26 Way Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6159 Totally Integrated Power Module C8 (Battery) 1 Way Connector C8 - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6160 MODULE-TOTALLY INTEGRATED POWER - (BATTERY) 1 WAY Totally Integrated Power Module C5 (Headlamp And Dash) 40 Way Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6161 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6162 Totally Integrated Power Module C6 (Headlamp And Dash) 40 Way Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6163 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6164 Totally Integrated Power Module C7 (Headlamp And Dash) 50 Way Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6165 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6166 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located on the right side of the engine compartment. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the TIPM mounting bracket by four clips integral to the TIPM housing. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description > Page 6169 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud with a nut. Internal connection of all the TIPM circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fuses, relays and TIPM housing assembly are available for service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 6172 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Position the front drivers seat to the full rearward position. 3. Remove the power inverter (2) mounting retainers (1) located under the carpet. 4. Disconnect the electrical connectors. 5. Remove the power inverter module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 6175 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Position the inverter into the vehicle and install mounting fasteners. 2. Connect the electrical connectors. 3. Connect the battery negative cable. 4. Position the front drivers seat back to the original position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 6176 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Release the Totally Integrated Power Module (TIPM) cover retaining clips and open the TIPM cover. 4. Remove the TIPM positive cable retaining nut and remove the cable from the stud. 5. Depress the four mounting clips to disengage and remove the TIPM housing from its mounting bracket. 6. Disconnect each of the seven TIPM wire harness connectors. 7. Remove the TIPM from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 6177 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from Dealer CONNECT 1. Position the TIPM into the engine compartment. 2. Connect each of the seven TIPM wire harness connectors. 3. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully seated. 4. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Tighten the nut to 9 - 11 Nm (80 - 100 in. lbs.). 5. Open the TIPM cover and fully seat the airbag fuse holder (two fuses in one yellow carrier) and the Ignition Off Draw (IOD) fuse. 6. Connect the battery negative cable. 7. Close the hood. 8. Insert the ignition key and turn it to the RUN position and wait twelve seconds. The TIPM will collect the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the OFF position and then back to the ON position and verify proper vehicle systems operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 6183 Power Distribution Module: Locations Totally Integrated Power Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 6184 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Inverter Module (Except Export) > Page 6185 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6188 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6189 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6190 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6191 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6192 Power Distribution Module: Diagrams Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6193 Power Distribution Module: Diagrams Inverter Module (Except Export) (Body) 9 Way Connector (EXCEPT EXPORT) - (BODY) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (BODY) 9 WAY Totally Integrated Power Module C1 (Headlamp And Dash) 50 Way Connector C1 - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6194 MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6195 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6196 Totally Integrated Power Module C3 (Front End Module) 26 Way Connector C3 - (FRONT END MODULE) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6197 Totally Integrated Power Module C4 (Front End Module) 16 Way Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6198 Module-Totally Integrated Power C1 Connector C1 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6199 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6200 Module-Totally Integrated Power C2 Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6201 Module-Totally Integrated Power C3 Connector C3 - (FRONT END MODULE) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6202 MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 26 WAY Module-Totally Integrated Power C4 Connector C4 - (FRONT END MODULE) 16 WAY MODULE-TOTALLY INTEGRATED POWER - (FRONT END MODULE) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6203 Module-Totally Integrated Power C5 Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6204 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6205 Module-Totally Integrated Power C6 Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6206 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6207 Module-Totally Integrated Power C7 Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6208 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6209 Totally Integrated Power Module C2 (Headlamp And Dash) 26 Way Connector C2 - (HEADLAMP AND DASH) 26 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 26 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6210 Totally Integrated Power Module C8 (Battery) 1 Way Connector C8 - (BATTERY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6211 MODULE-TOTALLY INTEGRATED POWER - (BATTERY) 1 WAY Totally Integrated Power Module C5 (Headlamp And Dash) 40 Way Connector C5 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6212 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6213 Totally Integrated Power Module C6 (Headlamp And Dash) 40 Way Connector C6 - (HEADLAMP AND DASH) 40 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6214 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6215 Totally Integrated Power Module C7 (Headlamp And Dash) 50 Way Connector C7 - (HEADLAMP AND DASH) 50 WAY MODULE-TOTALLY INTEGRATED POWER - (HEADLAMP AND DASH) 50 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6216 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Except Export) (Body) 9 Way > Page 6217 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located on the right side of the engine compartment. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the TIPM mounting bracket by four clips integral to the TIPM housing. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module (TIPM) - Description > Page 6220 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud with a nut. Internal connection of all the TIPM circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fuses, relays and TIPM housing assembly are available for service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 6223 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Position the front drivers seat to the full rearward position. 3. Remove the power inverter (2) mounting retainers (1) located under the carpet. 4. Disconnect the electrical connectors. 5. Remove the power inverter module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 6226 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Position the inverter into the vehicle and install mounting fasteners. 2. Connect the electrical connectors. 3. Connect the battery negative cable. 4. Position the front drivers seat back to the original position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 6227 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Release the Totally Integrated Power Module (TIPM) cover retaining clips and open the TIPM cover. 4. Remove the TIPM positive cable retaining nut and remove the cable from the stud. 5. Depress the four mounting clips to disengage and remove the TIPM housing from its mounting bracket. 6. Disconnect each of the seven TIPM wire harness connectors. 7. Remove the TIPM from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 6228 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from Dealer CONNECT 1. Position the TIPM into the engine compartment. 2. Connect each of the seven TIPM wire harness connectors. 3. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully seated. 4. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Tighten the nut to 9 - 11 Nm (80 - 100 in. lbs.). 5. Open the TIPM cover and fully seat the airbag fuse holder (two fuses in one yellow carrier) and the Ignition Off Draw (IOD) fuse. 6. Connect the battery negative cable. 7. Close the hood. 8. Insert the ignition key and turn it to the RUN position and wait twelve seconds. The TIPM will collect the necessary vehicle configuration and VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the OFF position and then back to the ON position and verify proper vehicle systems operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 6233 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 6234 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way Relay Box: Diagrams Run Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 6237 Relay Box: Diagrams Run/Accessory Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/ACCESSORY - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 6238 Relay Box: Diagrams Run/Start Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/START - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 6239 Relay Box: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 6240 Relay Box: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 6245 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Run Relay > Page 6246 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way Relay Box: Diagrams Run Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 6249 Relay Box: Diagrams Run/Accessory Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/ACCESSORY - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Run Relay (In TIPM) 5 Way > Page 6250 Relay Box: Diagrams Run/Start Relay (In TIPM) 5 Way Connector - (IN TIPM) 5 WAY RELAY-RUN/START - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 6251 Relay Box: Application and ID Integrated Power Module 8W-13-01 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 6252 Relay Box: Description and Operation DESCRIPTION An electrical Junction Block (JB) is located next to the Totally Integrated Power Module (TIPM). The JB combines the functions previously provided by a separate relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The junction block is replaced as part of the engine harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement Technical Service Bulletin # K07 Date: 110218 Recall - Front Door Wiring Harness Replacement February 2011 Dealer Service Instructions for: Safety Recall K07 Front Door Wiring Harnesses Safety Recall K07 Front Door Wiring Harnesses Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from November 01, 2007 through November 07, 2008 (MDH 110122 through 110723). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front door wiring harnesses on about 65,000 of the above vehicles may fatigue and break. Broken wires could interrupt the circuits for the side impact sensor(s) located inside the front doors. This could resulting in the illumination of the airbag warning lamp and loss of side crash sensing capability. Repair The right and left front door wiring harnesses must be replaced. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6261 These special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6262 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Open the hood. 2. Roll down both front door windows. 3. Disconnect and isolate the negative battery cable at the left shock tower. 4. Remove the front door window switch, grab handle cup, and release handle bezel (Figure 1). 5. Remove the front door panel (Figure 1). 6. Remove the front door inner window seal (Figure 1). 7. Separate the oval wiring harness grommet from the lower "A" pillar (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6263 8. Disconnect the body electrical connectors from the front door wiring harness (Figure 2). 9. Remove the two door grommet retaining screws (Figure 2). 10. Remove the door speaker from the door and disconnect the electrical connector (Figure 2). 11. Open the access door and disconnect the door latch electrical connector (Figure 3). 12. Disconnect the remaining electrical connectors and remove the front door wiring harness from the vehicle (Figure 2). CAUTION: Note the wiring harness routing before removing the wiring harness from the door. The new wiring harness must be routed in the same location as the original wiring harness. 13. Place the new front door wiring harness into position on the door. 14. Connect the front door wiring harness connectors to the body electrical connectors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6264 15. Snap the oval wiring harness grommet into the oval hole on the "A" pillar (Figure 1). 16. Place the door grommet into position and install the two retaining screws (Figure 1). 17. Connect the remaining electrical connectors to their respective modules/connectors (Figure 2). 18. Connect the door latch electrical connector and close the access door (Figure 3). 19. Connect the door speaker electrical connector and install the door speaker (Figure 4). 20. Install the front door inner window seal. 21. Install the front door panel. 22. Install the front door window switch, grab handle cup, and release handle bezel. 23. Repeat steps 4 through 22 on the other front door. 24. Connect the negative battery cable. 25. Using Mopar Total Clean or equivalent, clean both front door panels 26. On vehicles equipped with Express Window Up/Down (sales code JSC), perform Steps 27 through 30. 27. Connect the wiTECH to the vehicle. 28. Clear all Diagnostic Trouble Codes (DTC's). 29. Clear/Denormalize the door modules using the following procedures: a. Click on the "Miscellaneous Functions" tab. b. Select "Denormalize Window/Reset ECU" and follow the directions to clear/denormalize the door module memory. 30. Relearn/Normalize the door modules using the following procedure: a. Place the vehicle on a battery charger or have the engine running. b. Raise the front door glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the front door glass is fully closed. Continue to hold the window switch up for three seconds after the front door glass is fully closed. c. Lower the front door glass to the full-down position by pushing down (depress) the window switch to its second detent and hold the switch until the front door glass is fully open. Continue to hold the window switch down for three seconds after the front door glass is fully open. d. Check the operation of the express-up and express-down features. If the express-up feature does not work, repeat the procedure starting with Step 30b. e. Check that the front door glass reverses when in the express-up mode by holding a pen in the path of the glass. f. Repeat steps 30b. through 30e. on the other front door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6265 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA10V658000 > Dec > 10 > Recall 10V658000: Front Door Wiring Harnesses Wiring Harness: Recalls Recall 10V658000: Front Door Wiring Harnesses VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler Group LLC. MFR'S REPORT DATE: December 23, 2010 NHTSA CAMPAIGN ID NUMBER: 10V658000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System: Wiring POTENTIAL NUMBER OF UNITS AFFECTED: 65,180 SUMMARY: Chrysler is recalling certain model year 2009 Dodge Journey vehicles manufacturer from November 1, 2007, through September 7, 2008. The wires within the front door wire harnesses may fatigue and break, which can interrupt the circuits for the side impact sensor(s), resulting in an airbag warning lamp illumination and loss of side crash sensing capability. CONSEQUENCE: In the event of a crash, the side airbag may not deploy, reducing the protection intended for the occupant and increasing the risk of injuries. REMEDY: Chrysler will notify owners and replace the left and right door wiring harnesses free of charge. The safety recall is expected to begin during February 2011. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler safety recall No. K07. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing Technical Service Bulletin # H21 Date: 080701 Recall - Engine Wire Harness Routing July 2008 Dealer Service Instructions for: Safety Recall H21 Engine Wiring Harness Routing Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) # 08-040 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles equipped with a 3.5L engine ("V" in the 8th VIN Position) built from February 5, 2008 through March 14, 2008 (MDH 020506 through 031423). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine wiring harness on about 5,900 of the above vehicles may chafe on the left transaxle mount. This could cause a short circuit and result in an engine compartment fire. Repair The engine wiring harness must be inspected for damage, repaired if necessary and rerouted away from the left transaxle mount. Parts Information Due to the likelihood that the required plastic tie straps are already in your parts inventory, no plastic tie straps will be distributed initially. The following plastic tie strap is available as required. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6274 All dealers will receive one copy of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Disconnect the negative battery connection on the left shock tower. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6275 2. Inspect the engine wiring harness and, if equipped, the 120 volt engine block heater cord at the left transaxle mount for chafed wires (Figure 1): > If wire chafing is not found, continue with Step 6 of this procedure. > If wire chafing is found, continue with Step 3 of this procedure. 3. Remove the wiring harness protective tape from around the damaged area. 4. Repair wire(s) as required. 5. Install electrical tape around repaired area of wiring harness. 6. Disconnect the 14-way connector using the following procedure: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6276 a. Slide the red lock tab located on the top of the connector rearward (Figure 2). b. Push down on the black connector release tab. c. While pushing down on the black connector release tab pull the connector apart. 7. Wrap the harness side of the 14-way connector under and around the main wiring harness and reconnect the 14-way connector (Figure 3). Route the 120 volt engine block heater cord in the same manner, away from the left transaxle mount. CAUTION: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6277 Ensure that all wiring is routed away from all sharp edges. 8. Slide the red locking tab forward to lock the 14-way connector. 9. Connect the negative battery connection on the left shock tower. 10. Reposition the main wiring harness and, if equipped, the engine block heater cord. Secure them using a tie strap as shown in Figure 4. 11. Verify that the main wiring harness and, if equipped, the engine block heater cord do not touch the left transaxle mount or any other sharp edges. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6278 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement Technical Service Bulletin # K07 Date: 110218 Recall - Front Door Wiring Harness Replacement February 2011 Dealer Service Instructions for: Safety Recall K07 Front Door Wiring Harnesses Safety Recall K07 Front Door Wiring Harnesses Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from November 01, 2007 through November 07, 2008 (MDH 110122 through 110723). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front door wiring harnesses on about 65,000 of the above vehicles may fatigue and break. Broken wires could interrupt the circuits for the side impact sensor(s) located inside the front doors. This could resulting in the illumination of the airbag warning lamp and loss of side crash sensing capability. Repair The right and left front door wiring harnesses must be replaced. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6284 These special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6285 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Open the hood. 2. Roll down both front door windows. 3. Disconnect and isolate the negative battery cable at the left shock tower. 4. Remove the front door window switch, grab handle cup, and release handle bezel (Figure 1). 5. Remove the front door panel (Figure 1). 6. Remove the front door inner window seal (Figure 1). 7. Separate the oval wiring harness grommet from the lower "A" pillar (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6286 8. Disconnect the body electrical connectors from the front door wiring harness (Figure 2). 9. Remove the two door grommet retaining screws (Figure 2). 10. Remove the door speaker from the door and disconnect the electrical connector (Figure 2). 11. Open the access door and disconnect the door latch electrical connector (Figure 3). 12. Disconnect the remaining electrical connectors and remove the front door wiring harness from the vehicle (Figure 2). CAUTION: Note the wiring harness routing before removing the wiring harness from the door. The new wiring harness must be routed in the same location as the original wiring harness. 13. Place the new front door wiring harness into position on the door. 14. Connect the front door wiring harness connectors to the body electrical connectors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6287 15. Snap the oval wiring harness grommet into the oval hole on the "A" pillar (Figure 1). 16. Place the door grommet into position and install the two retaining screws (Figure 1). 17. Connect the remaining electrical connectors to their respective modules/connectors (Figure 2). 18. Connect the door latch electrical connector and close the access door (Figure 3). 19. Connect the door speaker electrical connector and install the door speaker (Figure 4). 20. Install the front door inner window seal. 21. Install the front door panel. 22. Install the front door window switch, grab handle cup, and release handle bezel. 23. Repeat steps 4 through 22 on the other front door. 24. Connect the negative battery cable. 25. Using Mopar Total Clean or equivalent, clean both front door panels 26. On vehicles equipped with Express Window Up/Down (sales code JSC), perform Steps 27 through 30. 27. Connect the wiTECH to the vehicle. 28. Clear all Diagnostic Trouble Codes (DTC's). 29. Clear/Denormalize the door modules using the following procedures: a. Click on the "Miscellaneous Functions" tab. b. Select "Denormalize Window/Reset ECU" and follow the directions to clear/denormalize the door module memory. 30. Relearn/Normalize the door modules using the following procedure: a. Place the vehicle on a battery charger or have the engine running. b. Raise the front door glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the front door glass is fully closed. Continue to hold the window switch up for three seconds after the front door glass is fully closed. c. Lower the front door glass to the full-down position by pushing down (depress) the window switch to its second detent and hold the switch until the front door glass is fully open. Continue to hold the window switch down for three seconds after the front door glass is fully open. d. Check the operation of the express-up and express-down features. If the express-up feature does not work, repeat the procedure starting with Step 30b. e. Check that the front door glass reverses when in the express-up mode by holding a pen in the path of the glass. f. Repeat steps 30b. through 30e. on the other front door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 6288 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA10V658000 > Dec > 10 > Recall 10V658000: Front Door Wiring Harnesses Wiring Harness: All Technical Service Bulletins Recall 10V658000: Front Door Wiring Harnesses VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler Group LLC. MFR'S REPORT DATE: December 23, 2010 NHTSA CAMPAIGN ID NUMBER: 10V658000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System: Wiring POTENTIAL NUMBER OF UNITS AFFECTED: 65,180 SUMMARY: Chrysler is recalling certain model year 2009 Dodge Journey vehicles manufacturer from November 1, 2007, through September 7, 2008. The wires within the front door wire harnesses may fatigue and break, which can interrupt the circuits for the side impact sensor(s), resulting in an airbag warning lamp illumination and loss of side crash sensing capability. CONSEQUENCE: In the event of a crash, the side airbag may not deploy, reducing the protection intended for the occupant and increasing the risk of injuries. REMEDY: Chrysler will notify owners and replace the left and right door wiring harnesses free of charge. The safety recall is expected to begin during February 2011. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler safety recall No. K07. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing Technical Service Bulletin # H21 Date: 080701 Recall - Engine Wire Harness Routing July 2008 Dealer Service Instructions for: Safety Recall H21 Engine Wiring Harness Routing Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) # 08-040 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles equipped with a 3.5L engine ("V" in the 8th VIN Position) built from February 5, 2008 through March 14, 2008 (MDH 020506 through 031423). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The engine wiring harness on about 5,900 of the above vehicles may chafe on the left transaxle mount. This could cause a short circuit and result in an engine compartment fire. Repair The engine wiring harness must be inspected for damage, repaired if necessary and rerouted away from the left transaxle mount. Parts Information Due to the likelihood that the required plastic tie straps are already in your parts inventory, no plastic tie straps will be distributed initially. The following plastic tie strap is available as required. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6297 All dealers will receive one copy of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Disconnect the negative battery connection on the left shock tower. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6298 2. Inspect the engine wiring harness and, if equipped, the 120 volt engine block heater cord at the left transaxle mount for chafed wires (Figure 1): > If wire chafing is not found, continue with Step 6 of this procedure. > If wire chafing is found, continue with Step 3 of this procedure. 3. Remove the wiring harness protective tape from around the damaged area. 4. Repair wire(s) as required. 5. Install electrical tape around repaired area of wiring harness. 6. Disconnect the 14-way connector using the following procedure: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6299 a. Slide the red lock tab located on the top of the connector rearward (Figure 2). b. Push down on the black connector release tab. c. While pushing down on the black connector release tab pull the connector apart. 7. Wrap the harness side of the 14-way connector under and around the main wiring harness and reconnect the 14-way connector (Figure 3). Route the 120 volt engine block heater cord in the same manner, away from the left transaxle mount. CAUTION: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6300 Ensure that all wiring is routed away from all sharp edges. 8. Slide the red locking tab forward to lock the 14-way connector. 9. Connect the negative battery connection on the left shock tower. 10. Reposition the main wiring harness and, if equipped, the engine block heater cord. Secure them using a tie strap as shown in Figure 4. 11. Verify that the main wiring harness and, if equipped, the engine block heater cord do not touch the left transaxle mount or any other sharp edges. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > H21 > Jul > 08 > Recall - Engine Wire Harness Routing > Page 6301 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Page 6302 Wiring Harness: Service and Repair GROMMET - A PILLAR 1. Peel the A Pillar grommet (1) off of the connector/retainer and move it up the wire harness. 2. Grasp the wire harness (2) by the convolute section of the grommet and gently pull the wire harness down towards the floor to expose the connector lock tabs. CAUTION: Do not force the locking tab past the connector body, as damage to the connector may occur. 3. While still pulling down on the harness, use a small slotted screw driver (3) to gently push one of the top lock tabs until the lock feature is flush with the connector/retainer body. 4. Repeat the step 3 for the remaining top lock tab. 5. The connector should now be able to rock out of the sheet metal hole without causing any damage to the connector or sheet metal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Curb Height Specifications Alignment: Specifications Curb Height Specifications CURB HEIGHT SPECIFICATIONS NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. Front - On each side of the vehicle, measure the distance (2) from the flat surface behind the PLP hole (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Curb Height Specifications > Page 6308 Rear - On each side of the vehicle, measure the distance (2) from the flat surface below the rear toe adjustment cam bolt (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. Compare the measurements to specifications listed in the CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6309 Alignment: Description and Operation DESCRIPTION Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when Chrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front - Camber (with cradle shift or service adjustment bolt package) - Caster (limited adjustment with cradle shift) - Toe Rear - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement for additional information. See: Service and Repair/Curb Height Measurement Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is known as negative camber. Outward tilt (1) is known as Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6310 positive camber. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. - Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7° and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2). CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. - Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. To achieve the cross caster reading, subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2). TOE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6311 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. - Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equal distant. TOE-OUT ON TURNS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6312 Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6313 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). - Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. See: WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. See: Specifications/Wheel Alignment Specifications REAR CAMBER Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, rear camber is not considered an adjustable angle. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles but some adjustment can be made. Camber and caster should be checked to ensure they meet vehicle specifications. See: Specifications/Wheel Alignment Specifications If individual front camber or caster is found not to meet alignment specifications, each can be adjusted by shifting the front crossmember or by using an available service adjustment bolt package. If an adjustment bolt package installation is necessary, inspect the suspension components for any signs of damage or bending first. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. ADJUSTMENT BY SHIFTING CROSSMEMBER CAUTION: Always use care when shifting crossmember to avoid damaging other components on the vehicle. 1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow movement of the crossmember. See: Suspension/Cross-Member/Service and Repair/Crossmember - Removal 2. Loosen the bolts fastening the fore/aft crossmember to the frame just enough to allow movement of the crossmember. See: Suspension/Cross-Member/Service and Repair/Crossmember - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6316 CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine mounts are attached to the front crossmember and fore/aft crossmember and should be inspected following the crossmember shift to make sure they are properly aligned. 3. Shift front crossmember as necessary (See following tables) to bring camber or caster into specifications. When shifting crossmember, use care not to move other angles (camber or caster) that are within specifications, out of specifications. 4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to specifications. See: Suspension/Cross-Member/Service and Repair/Crossmember - Installation 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure camber and caster. If camber and caster are within specifications, proceed to TOE. If camber cannot be brought into specifications, perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1). CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a punch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6317 3. Remove the original nuts (3, 4) and upper (1) and lower (6) bolts attaching the strut clevis bracket (2) to the knuckle (5). 4. Separate the knuckle (5) from the strut clevis bracket (2) and position knuckle so it is out of the way of the strut. Use care not to overextend the brake flex hose or axle half shaft. CAUTION: When slotting the bottom mounting hole (3) on the strut clevis bracket (4), do not enlarge the hole beyond the indentations (2) on the sides of the strut clevis bracket. 5. Using an appropriate grinder and grinding wheel, slot the bottom hole (3) in both sides of the strut clevis bracket (4). CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts. Only the service package bolts and dog bone washers must be used to attach the knuckle to the strut once the mounting hole is slotted. 6. Position the strut clevis bracket in line with the upper end of the knuckle, aligning the mounting holes. Install the two service package bolts. Be sure to place the bolt with the eccentric cam in the bottom (slotted) hole on strut clevis bracket. 7. Install the dog bone washers provided in the service package and nuts on the replacement bolts. Tighten each nut just enough to hold the knuckle in position while adjusting camber, but still allows the knuckle to move in the clevis bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6318 8. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Perform the above procedure to opposite side strut as required. 10. Lower the vehicle and jounce the front and rear of the vehicle. 11. Adjust the front camber to the preferred setting using the cam bolt in the lower mounting hole. Once camber is set to specifications, tighten the upper and lower strut service package bolt nuts to 140 Nm (103 ft. lbs.). Again jounce the front and rear of the vehicle, then verify the camber settings. 12. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to FRONT TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting front toe to the preferred specifications REAR TOE NOTE: Perform the following at each rear wheel as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6319 1. While holding the cam bolt head (4) stationary, loosen the toe link mounting cam bolt nut (3). 2. Rotate the cam bolt head (4) left or right until the rear wheel toe for that rear wheel is set to the preferred specification. See: Specifications/Wheel Alignment Specifications 3. While holding the cam bolt head (4) stationary, tighten the toe link mounting cam bolt nut (3) to 100 Nm (74 ft. lbs.). FRONT TOE NOTE: Perform the following at each front wheel as necessary. CAUTION: Do not twist the inner tie rod-to-steering gear boot (bellows) while turning the inner tie rod during front toe adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod. 1. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the other until the front wheel toe is set to the preferred specification. See: Specifications/Wheel Alignment Specifications 2. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 3. Make sure the inner tie rod-to-steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. 4. Remove the steering wheel clamp. 5. Remove the alignment equipment. 6. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6320 Alignment: Service and Repair Curb Height Measurement CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. Front - On each side of the vehicle, measure the distance 2 from the flat surface behind the PLP hole 1 to the floor or alignment rack/lift Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 6321 runway surface. It may be necessary to measure to the bottom of a straight edge 3, placed from lift runway to runway, to get an accurate measurement. 3. Rear - On each side of the vehicle, measure the distance 2 from the flat surface below the rear toe adjustment cam bolt 1 to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge 3, placed from lift runway to runway, to get an accurate measurement. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6332 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6333 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6334 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6335 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6336 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6337 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6338 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6339 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6345 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6346 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6347 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6348 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6349 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6350 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6351 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6352 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 6356 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6359 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C3 (Instrument Panel) 4 Way Connector C3 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6360 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6361 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C8 (Steering Wheel) 6 Way Connector C8 - (STEERING WHEEL) 6 WAY MODULE-STEERING CONTROL - (STEERING WHEEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (1), control knob and control sleeve that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions and electrical connections are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the SCM through a jumper wire harness (5) directly to the right (wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is integral to the back of the switch housing and connects the SCM to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function switch must be replaced. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6364 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6365 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM). The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch (with integral Steering Control Module) - Right Multi-Function Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6366 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Page 6367 Steering Mounted Controls Communication Module: Testing and Inspection STEERING CONTROL MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the Steering Control Module (SCM) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or the electronic controls or communication between modules and other devices that provide some features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel See: Steering/Steering Wheel/Service and Repair/Removal. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM)See: Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6370 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6371 7. Disconnect the right switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6372 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6373 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering/Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6374 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels and Tires/Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6382 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6383 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: Maintenance 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6386 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6387 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6388 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6389 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle (3) is a single casting with legs machined for attachment to the front strut assembly on the top and steering linkage on the trailing end. A ball joint is located on the bottom of the knuckle which attaches to the lower control arm. The knuckle also has two machined, drilled legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the hub and bearing (1). A shield (not shown in figure) is fastened to the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 6394 Front Steering Knuckle: Testing and Inspection KNUCKLE The front suspension knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the knuckle. Inspect the lower ball joint per the inspection procedure. The lower ball joint can be replaced separately from the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal Front Steering Knuckle: Service and Repair Front Steering Knuckle - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Suspension/Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6397 5. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5). 6. Remove the screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle. 7. Remove the nut (3) attaching the outer tie rod (6) to the knuckle (2). To do this it might be necessary to hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6398 8. Release the outer tie rod end (1) from the knuckle (3) using Remover (2), Special Tool 9360. 9. Remove the outer tie rod from the knuckle. 10. Remove the nut (4) attaching the lower ball joint to the lower control arm (5). 11. Release the lower ball joint (3) from the lower control arm (1) using Remover (2), Special Tool 9360. Do not lift the knuckle out of the lower control arm at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6399 CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method. 12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 14. Pull the knuckle (2) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6400 15. If required, remove the three screws (2) fastening the shield (3) to the knuckle (1). Remove the shield. 16. If required, remove the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). 17. If required, slide the hub and bearing (1) out of the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6401 Front Steering Knuckle: Service and Repair Front Steering Knuckle - Installation INSTALLATION 1. If required, install the hub and bearing (1) by sliding it into the knuckle. 2. If installing hub and bearing, install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 Nm (60 ft. lbs.). 3. If required, install the shield on the knuckle. Install and tighten the three mounting screws (2) to 10 Nm (89 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6402 4. Slide the hub and bearing in the knuckle (2) onto the splines of the half shaft outer C/V joint (1). 5. Insert the lower ball joint stud into the mounting hole in the lower control arm. 6. Install a NEW ball joint stud nut (4). Tighten the nut to 95 Nm (70 ft. lbs.). CAUTION: The strut clevis-to-knuckle bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step. 7. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5). 8. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 140 Nm (103 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6403 9. Install the outer tie rod (6) ball stud into the hole in the knuckle (2) arm. Start the tie rod end-to-knuckle nut (4) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 85 Nm (63 ft. lbs.). 10. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 Nm (106 in. lbs.). 11. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 12. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6404 13. Clean all foreign matter from the threads of the half shaft outer C/V joint. 14. Install the hub nut (1) on the end of the half shaft (2) and snug it. 15. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (3) to 132 Nm (97 ft. lbs.). 16. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 17. Lower the vehicle. 18. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > Customer Interest for Power Steering Bleeding: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns Power Steering Bleeding: Customer Interest Steering - Honk/Moan On Hard Left Hand Turns NUMBER: 19-001-09 GROUP: Steering DATE: January 22, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-08, DATED OCTOBER 11, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL YEARS AND MODELS. SUBJECT: Power Steering Honk, Moan Or Grinding Sound On Left Turns OVERVIEW: This bulletin involves replacing the power steering reservoir with a revised (taller) reservoir and bleeding the power steering system. MODELS: 2009 (JC) Journey **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin does not apply to vehicles built for Europe or Japan NOTE: This bulletin applies to **JC** vehicles built prior to September 3, 2008 (MDH 0903XX) **or JS vehicles built prior to January 29, 2009 (MDH 0129xx)**. SYMPTOM/CONDITION: The customers may hear a honk moan or grinding sound when performing hard left turns while accelerating or decelerating. DIAGNOSIS: If the above condition is present and determined to be coming from the power steering system, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING RESERVOIR REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering reservoir with the revised (taller) reservoir pn 05151028AA. 2. Refer to the detailed power steering system fill and bleed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 19 - Steering > Standard Procedure. NOTE: If vehicle still exhibits a honk sound on turns, there may still be air ingested into the steering system and the power steering bleeding procedure may have to be repeated several times. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > Customer Interest for Power Steering Bleeding: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns > Page 6414 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Bleeding: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns Power Steering Bleeding: All Technical Service Bulletins Steering - Honk/Moan On Hard Left Hand Turns NUMBER: 19-001-09 GROUP: Steering DATE: January 22, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-08, DATED OCTOBER 11, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL YEARS AND MODELS. SUBJECT: Power Steering Honk, Moan Or Grinding Sound On Left Turns OVERVIEW: This bulletin involves replacing the power steering reservoir with a revised (taller) reservoir and bleeding the power steering system. MODELS: 2009 (JC) Journey **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin does not apply to vehicles built for Europe or Japan NOTE: This bulletin applies to **JC** vehicles built prior to September 3, 2008 (MDH 0903XX) **or JS vehicles built prior to January 29, 2009 (MDH 0129xx)**. SYMPTOM/CONDITION: The customers may hear a honk moan or grinding sound when performing hard left turns while accelerating or decelerating. DIAGNOSIS: If the above condition is present and determined to be coming from the power steering system, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING RESERVOIR REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering reservoir with the revised (taller) reservoir pn 05151028AA. 2. Refer to the detailed power steering system fill and bleed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 19 - Steering > Standard Procedure. NOTE: If vehicle still exhibits a honk sound on turns, there may still be air ingested into the steering system and the power steering bleeding procedure may have to be repeated several times. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Bleeding: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns > Page 6420 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Bleeding: > Page 6421 Power Steering Bleeding: By Symptom Technical Service Bulletin # 19-001-09 Date: 090122 Steering - Honk/Moan On Hard Left Hand Turns NUMBER: 19-001-09 GROUP: Steering DATE: January 22, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-08, DATED OCTOBER 11, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL YEARS AND MODELS. SUBJECT: Power Steering Honk, Moan Or Grinding Sound On Left Turns OVERVIEW: This bulletin involves replacing the power steering reservoir with a revised (taller) reservoir and bleeding the power steering system. MODELS: 2009 (JC) Journey **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin does not apply to vehicles built for Europe or Japan NOTE: This bulletin applies to **JC** vehicles built prior to September 3, 2008 (MDH 0903XX) **or JS vehicles built prior to January 29, 2009 (MDH 0129xx)**. SYMPTOM/CONDITION: The customers may hear a honk moan or grinding sound when performing hard left turns while accelerating or decelerating. DIAGNOSIS: If the above condition is present and determined to be coming from the power steering system, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING RESERVOIR REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering reservoir with the revised (taller) reservoir pn 05151028AA. 2. Refer to the detailed power steering system fill and bleed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 19 - Steering > Standard Procedure. NOTE: If vehicle still exhibits a honk sound on turns, there may still be air ingested into the steering system and the power steering bleeding procedure may Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Bleeding: > Page 6422 have to be repeated several times. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 19-001-09 Date: 090122 Steering - Honk/Moan On Hard Left Hand Turns NUMBER: 19-001-09 GROUP: Steering DATE: January 22, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-08, DATED OCTOBER 11, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL YEARS AND MODELS. SUBJECT: Power Steering Honk, Moan Or Grinding Sound On Left Turns OVERVIEW: This bulletin involves replacing the power steering reservoir with a revised (taller) reservoir and bleeding the power steering system. MODELS: 2009 (JC) Journey **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin does not apply to vehicles built for Europe or Japan NOTE: This bulletin applies to **JC** vehicles built prior to September 3, 2008 (MDH 0903XX) **or JS vehicles built prior to January 29, 2009 (MDH 0129xx)**. SYMPTOM/CONDITION: The customers may hear a honk moan or grinding sound when performing hard left turns while accelerating or decelerating. DIAGNOSIS: If the above condition is present and determined to be coming from the power steering system, perform the Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Bleeding: > Page 6423 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING RESERVOIR REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering reservoir with the revised (taller) reservoir pn 05151028AA. 2. Refer to the detailed power steering system fill and bleed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 19 - Steering > Standard Procedure. NOTE: If vehicle still exhibits a honk sound on turns, there may still be air ingested into the steering system and the power steering bleeding procedure may have to be repeated several times. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Technical Service Bulletins > Page 6424 Power Steering Bleeding: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary.See: Service and Repair/Power Steering Fluid Level Checking 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to 1. 7. Repeat 1 through 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 6429 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6430 Power Steering Fluid: Specifications Power Steering Fluid ............................................................................... Mopar Power Steering Fluid +4, Mopar ATF +4 Automatic Transmission Fluid. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6431 Power Steering Fluid: Description and Operation POWER STEERING FLUID The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid. Both Fluids have the same material standard specifications (MS-9602). Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. The power steering system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. See: Service and Repair/Power Steering Fluid Level Checking Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6432 Power Steering Fluid: Service and Repair POWER STEERING FLUID LEVEL CHECKING WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from moving parts and to assure an accurate fluid level reading. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. NOTE: Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. The power steering fluid level can be viewed through the side of the power steering fluid reservoir. Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the MAX. line. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation Power Steering Fluid Cooler: Description and Operation DESCRIPTION The cooler (3) is placed in series with the power steering fluid return hose, between the steering gear fluid outlet port and the fluid return hose leading to the power steering fluid reservoir. It is attached to the front bumper reinforcement (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Cooler - Removal Power Steering Fluid Cooler: Service and Repair Power Steering Cooler - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise and support the vehicle. See: Maintenance. 3. If equipped, remove the belly pan below the engine. 4. Remove the lower fascia valance. 5. Remove the hose clamps (5) attaching the fluid return hoses (1) to the power steering fluid cooler line (3). Separate the return hoses from the cooler line. 6. Remove the two cooler mounting push pins (4) at the bumper reinforcement (2). 7. Remove the cooler line (3) from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Cooler - Removal > Page 6438 Power Steering Fluid Cooler: Service and Repair Power Steering Cooler - Installation INSTALLATION 1. Install the power steering fluid cooler line (3) to the bumper reinforcement (2) by installing the two cooler mounting push pins (4). 2. Install the fluid return hoses (1) on the cooler line (3). Install the hose clamps (5) on the hoses past the bead formed into the end of the cooler tube and secure in place. 3. Install the lower fascia valance. 4. If equipped, install the belly pan below the engine. 5. Lower the vehicle. 6. Fill and bleed the power steering system. See: Service and Repair/Steering - Power Steering System Bleeding 7. Check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Reservoir: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns Power Steering Fluid Reservoir: Customer Interest Steering - Honk/Moan On Hard Left Hand Turns NUMBER: 19-001-09 GROUP: Steering DATE: January 22, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-08, DATED OCTOBER 11, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL YEARS AND MODELS. SUBJECT: Power Steering Honk, Moan Or Grinding Sound On Left Turns OVERVIEW: This bulletin involves replacing the power steering reservoir with a revised (taller) reservoir and bleeding the power steering system. MODELS: 2009 (JC) Journey **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin does not apply to vehicles built for Europe or Japan NOTE: This bulletin applies to **JC** vehicles built prior to September 3, 2008 (MDH 0903XX) **or JS vehicles built prior to January 29, 2009 (MDH 0129xx)**. SYMPTOM/CONDITION: The customers may hear a honk moan or grinding sound when performing hard left turns while accelerating or decelerating. DIAGNOSIS: If the above condition is present and determined to be coming from the power steering system, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING RESERVOIR REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering reservoir with the revised (taller) reservoir pn 05151028AA. 2. Refer to the detailed power steering system fill and bleed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 19 - Steering > Standard Procedure. NOTE: If vehicle still exhibits a honk sound on turns, there may still be air ingested into the steering system and the power steering bleeding procedure may have to be repeated several times. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Reservoir: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns > Page 6447 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Reservoir: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns Power Steering Fluid Reservoir: All Technical Service Bulletins Steering - Honk/Moan On Hard Left Hand Turns NUMBER: 19-001-09 GROUP: Steering DATE: January 22, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-002-08, DATED OCTOBER 11, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL YEARS AND MODELS. SUBJECT: Power Steering Honk, Moan Or Grinding Sound On Left Turns OVERVIEW: This bulletin involves replacing the power steering reservoir with a revised (taller) reservoir and bleeding the power steering system. MODELS: 2009 (JC) Journey **2007 - 2009 (JS) Sebring/Avenger/Sebring Convertible** NOTE: **This bulletin does not apply to vehicles built for Europe or Japan NOTE: This bulletin applies to **JC** vehicles built prior to September 3, 2008 (MDH 0903XX) **or JS vehicles built prior to January 29, 2009 (MDH 0129xx)**. SYMPTOM/CONDITION: The customers may hear a honk moan or grinding sound when performing hard left turns while accelerating or decelerating. DIAGNOSIS: If the above condition is present and determined to be coming from the power steering system, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING RESERVOIR REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering reservoir with the revised (taller) reservoir pn 05151028AA. 2. Refer to the detailed power steering system fill and bleed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 19 - Steering > Standard Procedure. NOTE: If vehicle still exhibits a honk sound on turns, there may still be air ingested into the steering system and the power steering bleeding procedure may have to be repeated several times. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Reservoir: > 19-001-09 > Jan > 09 > Steering - Honk/Moan On Hard Left Hand Turns > Page 6453 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Technical Service Bulletins > Page 6454 Power Steering Fluid Reservoir: Description and Operation DESCRIPTION The power steering fluid reservoir (5) is mounted above the right front inner fender well to a bracket (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Reservoir, Power Steering Pump - Removal Power Steering Fluid Reservoir: Service and Repair Reservoir, Power Steering Pump - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions . 1. Remove engine appearance cover. 2. Remove the fasteners securing the coolant recovery bottle to its mounts and move it away from the power steering fluid reservoir. It is not necessary to disconnect the coolant recovery bottle fluid lines. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal 3. Siphon as much fluid as possible from the power steering fluid reservoir (5). 4. Remove hose clamp securing cooler return hose (3) to fluid reservoir fitting. Slide the hose off the end of the reservoir fitting. 5. Remove hose clamp securing pump supply hose (4) to the fluid reservoir fitting. Slide the hose off the end of the reservoir fitting. 6. Remove the reservoir mounting screw (1) used to secure the reservoir in place. 7. Remove the reservoir (5). 8. Remove the plastic shield from the reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Reservoir, Power Steering Pump - Removal > Page 6457 Power Steering Fluid Reservoir: Service and Repair Reservoir, Power Steering Pump - Installation INSTALLATION 1. Install the plastic shield over the reservoir neck. 2. Attach the reservoir (5) to the strut tower bracket (2) using the mounting screw (1). Tighten mounting screw (1) to 12 Nm (106 in. lbs.). 3. Slide the pump supply hose (4) onto reservoir fitting. Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past bead formed into fluid reservoir fitting. 4. Slide cooler return hose (3) onto reservoir fitting. Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past bead formed into fluid reservoir fitting. 5. Install the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation 6. Fill and bleed the power steering system. See: Service and Repair/Steering - Power Steering System Bleeding 7. Check for leaks. 8. Install the engine appearance cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Testing and Inspection Power Steering Line/Hose: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection/Component Tests and General Diagnostics CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. See: Power Steering Pump/Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal Power Steering Line/Hose: Service and Repair Power Steering Hose - Removal Pressure Hose 3.5L ENGINE NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Raise and support the vehicle See: Maintenance. 4. Unscrew the tube nut (3), then remove the pressure hose (4) at the steering gear. 5. Lower the vehicle. 6. Unscrew the tube nut (3), then remove the pressure hose (1) at the pump (4). 7. Remove the pressure hose routing clamp bolt (2) at the engine cylinder head. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6463 8. Accessing it through the area behind the powertrain control module (3), remove the routing clamp screw (2) securing the pressure hose (1) to the left side of the front suspension crossmember. 9. Remove the power steering pressure hose from the vehicle. Return Hose REMOVAL NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the power steering fluid reservoir.See: Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal 3. Remove the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal 4. Raise and support the vehicle. See: Maintenance 5. If equipped, remove the belly pan below the engine. 6. Remove the lower fascia valance. 7. Remove the return hose (1) at the return tube (2). If equipped with a screw-clamp, be sure to save the original clamp for reinstallation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6464 8. Remove the hose clamps (5) attaching the fluid return hoses (7) to the power steering fluid cooler line (4). Separate the return hoses from the cooler line. 9. Remove the return hose routing clamp screws (3) securing the return hose (7) to the frame rail. 10. Remove the return hose routing clamp screw (6) securing the return hose (7) to the frame rail. 11. Lower the vehicle. 12. Remove the return hose routing clamp screw (1) securing the return hose (7) to the body. 13. Remove the return hose from the vehicle. Supply Hose 3.5L ENGINE NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the clamp (3) securing the supply hose (2) to the power steering pump supply fitting (4), then remove the hose from the supply fitting. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6465 3. Remove the mounting screws (1) securing the coolant recovery container (4) in place. 4. Lift the coolant recovery container as high as its connected hoses will allow, then remove the clip (6) securing the supply hose to the coolant recovery container's lower mounting point. 5. Remove the hose clamp (1) securing the supply hose (2) to the power steering fluid reservoir (7). Slide the hose off the end of the reservoir fitting and remove from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6466 Power Steering Line/Hose: Service and Repair Power Steering Hose - Installation Pressure Hose 3.5L ENGINE CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts, vehicle components and any unfriendly surface that can possibly damage the hoses. 1. Install the pressure hose into the engine compartment from above between the engine and the upper radiator hose. Then route the hose down the left side of the engine above the transmission, down to the steering gear. 2. Raise and support the vehicle See: Maintenance. 3. Install the pressure hose tube (4) at the gear. Tighten the tube nut (3) to 32 Nm (24 ft. lbs.). 4. Lower the vehicle. 5. Accessing it through the area behind the powertrain control module (3), position the power steering hose (1) routing clamp at the left side of the front suspension crossmember. Install and tighten the routing clamp screw (2) to 14 Nm (10 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6467 6. Using a lint free towel, wipe clean the open power steering pressure hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid. 7. Install the pressure hose (1) at the power steering pump (4). Tighten the tube nut (3) to 32 Nm (24 ft. lbs.). 8. Position the pressure hose (1) routing clamp at the engine cylinder head. Install and tighten the routing clamp bolt (2) to 22 Nm (16 ft. lbs.). 9. Fill and bleed the power steering system See: Service and Repair/Steering - Power Steering System Bleeding. 10. Check for leaks. Return Hose INSTALLATION 1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose routing clamp screw (1) securing the return hose (7) to the body. 3. Raise and support the vehicle. See: Maintenance 4. Install the return hose routing clamp screw (6) securing the return hose (7) to the frame rail. Tighten the screw to 8 Nm (71 in. lbs.). 5. Install the screws (3) securing the return hose to the frame rail (2). Tighten the screws to 8 Nm (71 in. lbs.). 6. Install the return hose onto the cooler line (4) and install the hose clamps (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6468 7. Install the return hose (1) at the return tube (2) and install the clamp. If a screw-clamp is used, tighten it to 2.5 Nm (20 in. lbs.). 8. Install the lower fascia valance. 9. If equipped, install the belly pan below the engine. 10. Lower the vehicle. 11. Install the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation 12. Install the power steering fluid reservoir. See: Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation 13. Fill and bleed the power steering system. See: Service and Repair/Steering - Power Steering System Bleeding 14. Check for leaks. Supply Hose 3.5L ENGINE 1. Slide hose clamps (1, 3) onto the ends of the power steering fluid supply hose (2) far enough to clear the fittings on the reservoir and pump once the hose is installed. 2. Place the pump end of the supply hose onto the pump supply fitting (4). Expand the hose clamp (3) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 3. Lift the coolant recovery container as high as its connected hoses will allow, then install the clip (6) in the mounting hole (5) securing the supply hose to the coolant recovery container's lower mounting point. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6469 4. Lower the coolant recovery container (4) to its mounted position and install the mounting screws (1). 5. Place the fluid reservoir end of the supply hose (2) onto the reservoir (7) supply fitting. Expand the hose clamp and slide it over the hose and fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 6. Fill and bleed the power steering system. See: Service and Repair/Steering - Power Steering System Bleeding 7. Check for leaks. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Power Steering Pump: Customer Interest Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 6478 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine Power Steering Pump: All Technical Service Bulletins Engine Controls/Steering - Power Steering Whine NUMBER: 19-001-08 GROUP: Steering DATE: April 3, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER. StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: Flash: Power Steering Whine Sound / Coordinated Hardware Change OVERVIEW: This bulletin involves replacing the Power Steering Pump with a revised part and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to models equipped with a 3.5L engine (Sales Codes EGF) built prior to February 29, 2008 (MDH0229XX). SYMPTOM/CONDITION: Some customers may hear a high pitched whine sound between 1200 and 2000 engine RPM. The whine may be most noticeable when accelerating from a stop. DIAGNOSIS: Start the engine and raise the engine speed to between 1200 and 2000 RPM. With the RPM raised, listen for a high pitched whine sound. If a high pitched whine is heard and determined to be coming from the power steering system, perform the Repair Procedure. NOTE: Do not move the steering wheel during the test. The whine sound is heard with no load on the power steering pump. PARTS REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-001-08 > Apr > 08 > Engine Controls/Steering - Power Steering Whine > Page 6484 NOTE: If a power steering pump is replaced for other reasons on any vehicle built prior to February 29, 2008. The PCM will require update to take full advantage of the power steering pump change and provide the appropriate Idle RPM assist during low speed parking lot maneuvers. Failure to update the software may result in inappropriate low speed power steering assist feel. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - POWER STEERING PUMP REPLACEMENT: 1. Using the procedures outlined in DealerCONNECT > TechCONNECT, replace the power steering pump with pn 05151835AB.. REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The software update must be made to take full advantage of the power steering pump change and provide the appropriate idle RPM assist during low speed parking lot maneuvers. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Power Steering Pump - Description Power Steering Pump: Description and Operation Power Steering Pump - Description DESCRIPTION Hydraulic pressure for operation of the power steering gear is provided by a droop-flow type power steering pump. The power steering pump is belt driven. The pulley (1) cannot be serviced separately on four-cylinder engine mounted pumps. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Power Steering Pump - Description > Page 6487 Power Steering Pump: Description and Operation Power Steering Pump Pulley - Description DESCRIPTION The pulley mounted on power steering pumps used on six cylinder engines can serviced separately from the pump. It has a center hub incorporating a flange used for pump removal. The pulley used on pumps mounted on four cylinder engines is not serviced separately. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Page 6488 Power Steering Pump: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection/Component Tests and General Diagnostics CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. See: Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal Power Steering Pump: Service and Repair Power Steering Pump - Removal 3.5L ENGINE NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Unscrew the tube nut (3), then remove the pressure hose (1) at the pump (4). 4. Remove the pressure hose routing clamp bolt (2) at the engine cylinder head. 5. Remove the clamp (3) securing the supply hose (2) to the power steering pump supply fitting (4), then remove the hose from the supply fitting. 6. Raise and support the vehicle. See: Maintenance Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6491 7. Remove the wheel mounting nuts (3), then the right front tire and wheel assembly (1). 8. Remove the drive belt splash shield. 9. Remove the drive belt. See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 10. Lower the vehicle. 11. Remove the two nuts securing the right engine mount bracket to the mount. 12. Position a floor jack (3) with an appropriate size block of wood (2) below the engine oil pan (1). raise the jack until the block of wood just comes into contact with the bottom of the oil pan, but no further. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6492 13. Slowly raise the right side of the engine using the floor jack while viewing the pump drive pulley. Raise the engine until all three power steering pump mounting bolts can be accessed through the openings in the drive pulley. 14. Remove the three pump mounting bolts through the pulley openings. 15. Remove the power steering pump. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6493 Power Steering Pump: Service and Repair Power Steering Pump - Installation 3.5L ENGINE 1. Using a lint free towel, wipe clean the open power steering pressure hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid. 2. Place the pump in mounted position. Install the three bolts through the pulley openings. Tighten the mounting bolts to 30 Nm (22 ft. lbs.). 3. Slowly lower the right side of the engine using the floor jack, guiding the right engine mount bracket mounting holes over the mounting studs of the right engine mount. 4. Remove the floor jack and block of wood from below engine. 5. Install the two nuts securing the right engine mount bracket to the mount.See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator - Installation 6. Raise and support the vehicle. See: Maintenance 7. Install the drive belt. See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 8. Install the drive belt splash shield. 9. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6494 11. Place the pump end of the supply hose (2) onto the pump supply fitting (4). Expand the hose clamp (3) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 12. Install the pressure hose (1) at the power steering pump (4). Tighten the tube nut (3) to 32 Nm (24 ft. lbs.). 13. Position the pressure hose (1) routing clamp at the engine cylinder head. Install and tighten the routing clamp bolt (2) to 22 Nm (16 ft. lbs.). 14. Fill and bleed the power steering system. See: Service and Repair/Steering - Power Steering System Bleeding 15. Check for leaks. 16. Install the engine appearance cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6495 Power Steering Pump: Service and Repair Power Steering Pump Pulley - Removal REMOVAL 1. Remove power steering pump from engine. See: Power Steering Pump - Removal CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. Damage to pulley and power steering pump will occur. CAUTION: It is very important to use Puller 9962, to remove pulley from power steering pump shaft. Use of other pullers can damage or break pulley and pump shaft. 2. Coat Screw-Drive (1) with lubricant and thread into Puller Body (2). NOTE: Two Buttons come with Puller kit (9962-3 and 9962-4). Be sure to use Button that best fits end of pump shaft to avoid damage to Button or pump shaft. 3. Insert Button 9962-4 (4), into end of Screw-Drive. Be sure not to misplace ball bearing that resides behind Button. 4. Assemble Puller 9962, over end of pump shaft and pulley hub. a. Place Button on end of Screw-Drive against pump shaft. b. Assemble Collets 9962-2 (3), surrounding Puller Body (1) and pulley hub flange, then slide the Collet Sleeve over the Collets. c. Hand tighten Screw-Drive (2) taking up any slack in Puller. 5. Hold Puller Body stationary while turning Screw-Drive until pulley is removed from power steering pump shaft. NOTE: Inspect pulley. Replace if pulley is bent, cracked, or loose. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6496 Power Steering Pump: Service and Repair Power Steering Pump Pulley - Installation INSTALLATION CAUTION: Do not hammer on power steering pump pulley (2) or pump shaft to install pulley. This action will damage pulley and power steering pump. 1. Place power steering pump pulley (2) squarely on end of power steering pump shaft. 2. Place Installation Spacer 6936 (1), on top of pump pulley (2). NOTE: Later build pumps feature a shaft with internal threads that are not as deep as earlier production, thus requiring a stack of washers, approximately 13 mm (0.5 in.) thickness (3), placed over Spacer 6936 (2), before mounting Installer C-4063C (1) on the pump. To know if a replacement pump requires the stack of washers, measure the depth of the shaft hole. A later build pump will have a depth of 20 mm (0.78 in.) while an earlier build pump will have a depth of 32 mm (1.25 in.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6497 3. As necessary (see above note), place a stack of washers approximately 13 mm (0.5 in.) thickness (3) over Spacer 6936 (2). NOTE: It is important to use Forcing Screw C-4063-2 when performing this procedure. 4. Thread Installer C-4063C (1), completely into internal threads of power steering pump shaft, then rotate Installer Nut down against washers (as necessary) and Spacer (2) on pump pulley. 5. Ensuring that the tools and pulley remain aligned with pump shaft, tighten Installer Nut, forcing pulley onto power steering pump shaft until Spacer (2) comes in contact with end of pump shaft. When Spacer (2) is against shaft of power steering pump, Installer (1) Nut will no longer rotate. 6. Install power steering pump on engine.See: Power Steering Pump - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6507 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6508 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6509 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6510 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6511 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6512 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6513 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6514 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6520 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6521 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6522 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6523 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6524 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6525 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6526 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6527 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 6531 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6534 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C3 (Instrument Panel) 4 Way Connector C3 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6535 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6536 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C8 (Steering Wheel) 6 Way Connector C8 - (STEERING WHEEL) 6 WAY MODULE-STEERING CONTROL - (STEERING WHEEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (1), control knob and control sleeve that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions and electrical connections are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the SCM through a jumper wire harness (5) directly to the right (wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is integral to the back of the switch housing and connects the SCM to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function switch must be replaced. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description > Page 6539 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description > Page 6540 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM). The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch (with integral Steering Control Module) - Right Multi-Function Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description > Page 6541 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Page 6542 Steering Mounted Controls Communication Module: Testing and Inspection STEERING CONTROL MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the Steering Control Module (SCM) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or the electronic controls or communication between modules and other devices that provide some features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel See: Steering Wheel/Service and Repair/Removal. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM)See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 6545 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 6546 7. Disconnect the right switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 6547 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 6548 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 6549 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6559 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6560 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6561 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6562 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6563 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6564 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6565 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > Recalls for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6566 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect Technical Service Bulletin # J13 Date: 090609 Recall - Steering Column Control Module Defect May 2009 Dealer Service Instructions for: Safety Recall J13 Steering Column Control Module Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from February 09, 2009 through February 24, 2009 (MDH 020916 through 022417). 2009 (JK) Jeep(R) Wrangler NOTE: This recall applies only to the above vehicles built from February 10, 2009 through February 26, 2009 (MDH 021008 through 022608). 2009 (WK) Jeep(R) Grand Cherokee (XK) Jeep(R) Commander NOTE: This recall applies only to the above vehicles built from February 19, 2009 through February 25, 2009 (MDH 021910 through 022509). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Steering Column Control Module (SCCM) on about 4,300 of the above vehicles may have the squib connector wiring reversed for the driver airbag module. This could cause the driver side airbag not to deploy as intended and increase the risk of injury during a crash. Repair The Steering Column Control Module build date code must be inspected on all vehicles. Those vehicles that have Steering Column Control Modules with a Julian date code of 0409, 0419, or 0429 must receive an additional inspection on the driver airbag squib wires. Steering Column Control Modules with suspect driver airbag squib wires must be replace. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that Steering Column Control Module replacement is required and the vehicle must be held overnight. Parts Information There will be no initial parts distribution. Parts should only be ordered after inspection determines the need for replacement. Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6572 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6573 approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure A. Inspect Steering Column Control Module Data Label 1. Turn the steering wheel to the 6 o'clock position (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6574 2. Unsnap the knee bolster at the top of the bolster and allow it to hinge downward (Figure 2). 3. Remove the upper and lower plastic steering column shrouds. 4. Inspect the first four digits of the Julian data code (disregard the fifth digit) on the label located on the bottom of the Steering Column Control Module (Figure 3) for the following: > If the Julian date code on the bar code data label is 0409, 0419, or 0429 continue with Section B. Inspect Steering Column Control Module Wiring Orientation. > If the Julian date code on the bar code data label is not 0409, 0419, or 0429 the Steering Column Control Module does not require further inspection or replacement. Continue with Step 5 of this procedure. 5. Install the steering column cover shrouds. 6. Install the knee bolster. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6575 7. Return the vehicle to the customer. B. Inspect Steering Column Control Module Wiring Orientation WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting Steering Column Control Module replacement. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before proceeding. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the negative battery cable, then wait two minutes before proceeding. 2. Place the steering wheel in the straight ahead position. NOTE: The front wheels must also be in the straight ahead position. 3. Separate the driver airbag module from the steering wheel but do not disconnect the driver airbag module squib wires. CAUTION: Do not allow the driver airbag module to hang by the squib wires. NOTE: Some models use three clips to hold the driver airbag module to the steering wheel (Figure 4). 4. Remove the black electrical tape that holds the two sets of squib wires together (Figure 5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6576 5. Inspect the driver airbag module squib wiring orientation going into the Steering Column Control Module (Figure 6): > If the pair of red and blue wires going into the Steering Column Control Module enter on the left side and the pair of yellow and brown wires enter on the right side, the Steering Column Control Module does not require repair. Continue with Step 6 of this procedure. > If the pair of red and blue wires going into the Steering Column Control Module enter on the right side and the pair of yellow and brown wires enter on the left side, the Steering Column Control Module is defective and must be replaced. Continue with Section C. Replace Steering Column Control Module. 6. Install the driver airbag module onto the steering wheel. 7. Install the steering column cover shrouds. 8. Install the knee bolster. 9. Connect the negative battery cable. 10. Return the vehicle to the customer. C. Replace Steering Column Control Module CAUTION: The clockspring in the Steering Column Control Module is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin must not be removed until the steering wheel has been installed on the steering column (Step 20). 1. Disconnect the driver airbag module wires and place the module aside. 2. Disconnect the white steering wheel wiring connector. 3. Remove the steering wheel retaining bolt. 4. Remove the steering wheel from the steering shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6577 5. Move the steering column to the fully lowered position. 6. Remove the three screws that secure the Steering Column Control Module to the steering column bracket. 7. Pull the Steering Column Control Module away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors from the receptacles on the back of the Steering Column Control Module case. 8. Remove the Steering Column Control Module from the steering column. 9. Transfer the right multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 7). 10. Transfer the left multi-function switch from the old Steering Column Control Module to the new Steering Column Control Module (Figure 8). 11. Transfer the multi-function switch jumper harness from the old Steering Column Control Module onto the new Steering Column Control Module (Figure 8). CAUTION: Make sure that the jumper wire connectors are locked in place by gently pulling on them. 12. Carefully slide the Steering Column Control Module down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors to the receptacles on the back of the Steering Column Control Module case. 13. Position the Steering Column Control Module onto the steering column bracket. 14. Install and tighten the three screws that secure the Steering Column Control Module to the steering column bracket to 27 in. lbs. (3 N.m) in the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6578 following sequence: > Lower right screw > Upper left screw > Upper right screw CAUTION: Use of an improper sequence when tightening the Steering Column Control Module mounting screws may result in an audible ticking noise as the steering wheel is rotated. 15. Install the upper and lower shrouds onto the steering column. 16 Install the knee bolster. 17. Move the steering column back to the fully raised position and move the tilt release lever to the locked position. 18. Install the steering wheel onto the steering column. 19. Install the steering wheel retaining bolt and tighten bolt to 45 ft. lbs. (61 N.m). 20. Remove the plastic locking pin that secures the clockspring rotor to the Steering Column Control Module case. 21. Connect the white steering wheel wiring connector. 22. Connect the squib connectors to the driver airbag module. 23. Install the driver airbag module to the steering wheel. 24. Perform the Supplemental Restraints Verification Test below: a. Connect the scan tool to the 16-way data link connector located on the driver's side lower edge of the instrument panel. b. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. c. Check and make certain that nobody is in the vehicle, then reconnect the negative battery cable. d. Using the scan tool, read and record active and historical Diagnostic Trouble Codes (DTC's). e. Use the scan tool to erase the stored DTC's. f. Turn the ignition to the "OFF" position for about 15 seconds, and then back to the "ON" position. Observe the airbag indicator lamp in the instrument cluster. It should light for six to eight seconds and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. g. Remove the scan tool from the vehicle. h. Return the vehicle to the customer. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Control Module: > J13 > Jun > 09 > Recall - Steering Column Control Module Defect > Page 6579 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal Steering Column Cover: Service and Repair Steering Column Shroud - Removal Upper REMOVAL 1. Position the column tilt at the full-upward position. 2. Remove the steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1). 4. Position the column tilt at the full-downward position. Leave the tilt lever (2) in the released position. 5. Remove the screws (1) attaching the lower shroud. After removing the screws, un-clip the shrouds from one another by applying hand pressure along the seams where the shrouds connect on the sides. 6. Remove the lower shroud. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 6584 NOTE: The gap hider on the upper shroud is attached to the instrument cluster (1) by four retaining tabs (2) along the top and two along the sides (one each side). These tabs can be easily released by hand in the following step. Do not use a tool that could damage the gap hider. 7. Pull the column outward to the full-extended position. 8. Reach up behind the shroud gap hider (1) and release the two side and four upper tabs retaining the shroud gap hider to the instrument cluster (2). 9. Remove the upper shroud from the column. Lower REMOVAL 1. Position the column tilt at the full-upward position. 2. Remove the steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 6585 3. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1). 4. Position the column tilt at the full-downward position. Leave the tilt lever (2) in the released position. 5. Remove the screws (1) attaching the lower shroud. After removing the screws, un-clip the shrouds from one another by applying hand pressure along the seams where the shrouds connect on the sides. 6. Remove the lower shroud. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 6586 Steering Column Cover: Service and Repair Steering Column Shroud - Installation Upper INSTALLATION 1. Position the upper shroud over the steering column. 2. Align the four upper shroud gap hider retaining tabs (2) with the mounting holes in the instrument cluster (1), then push the tabs upward, securing the shroud. 3. Align the two shroud gap hider side retaining tabs (one each side) with the mounting holes, then push the tabs into place, securing the shroud. 4. Push the column tilt lever (2) downward (released position). 5. Install the lower shroud (2) over the tilt lever and onto the column. 6. Install the upper shroud onto the lower shroud, clipping the shrouds to one another. 7. Install the three screws (1) attaching the lower shroud to the steering column. 8. Position the column tilt (5) at the full-upward position. 9. Push the tilt lever upward, locking the column in place. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 6587 10. Install the steering column cover reinforcement (1) using the four mounting screws (2). 11. Install the steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. Lower INSTALLATION 1. Push the tilt lever (2) downward (released position). 2. Install the lower shroud (2) over the tilt lever and onto the column. 3. Install the upper shroud onto the lower shroud, clipping the shrouds to one another. 4. Install the three screws (1) attaching the lower shroud to the steering column. 5. Position the column tilt (5) at the full-upward position. 6. Push the tilt lever upward, locking the column in place. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 6588 7. Install the steering column cover reinforcement (1) using the four mounting screws (2). 8. Install the steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Locations > Page 6592 Steering Column Lock: Diagrams Connector (VTSA) - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING COLUMN-LOCK (VTSA) - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Description and Operation > Shaft Lock Module - Description Steering Column Lock: Description and Operation Shaft Lock Module - Description DESCRIPTION A shaft lock module (1) is part of the premium version of the Sentry Key Immobilizer System (SKIS) in the Vehicle Theft Security System (VTSS). The premium version of the SKIS is only available in vehicles built for certain markets, where the additional features offered by this system are required. The shaft lock module is located in a bracket integral to the lower end of the steering column housing casting below the instrument panel in the passenger compartment. This unit is designed to work in conjunction with the Wireless Ignition Node (WIN), sometimes referred to as the Sentry Key REmote Entry Module (SKREEM) to control a locking bolt (2) that engages a machined slot in the steering shaft to prevent shaft rotation whenever there is not a valid key present in the ignition lock cylinder on the instrument panel. Concealed within the module is the electronic circuitry of the module, and a bi-directional electric motor that actuates the locking bolt. The module is connected to the vehicle electrical system through the instrument panel wire harness. The mounting provisions for the shaft lock module are designed to resist unauthorized tampering. The module cannot be removed from the steering column while the locking bolt is in the locked position, or while the steering column is installed in the vehicle. The shaft lock module unit cannot be adjusted or repaired and, if ineffective or damaged, the entire steering column must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Description and Operation > Shaft Lock Module - Description > Page 6595 Steering Column Lock: Description and Operation Shaft Lock Module - Operation OPERATION The electronic circuitry within the shaft lock module contains all of the logic circuits and components to monitor and control the operation of the shaft locking bolt. The module uses a serial data bus for bi-directional communication with the Wireless Ignition Node (WIN) , sometimes referred to as the Sentry Key REmote Entry Module (SKREEM). If the module detects a problem with the positioning or operation of the locking bolt, it sends an error message to the WIN. The WIN then stores a Diagnostic Trouble Code (DTC) and sends an electronic error message to the Instrument Cluster, sometimes referred to as the Cab Compartment Node (CCN), over the Controller Area Network (CAN) data bus. The shaft lock module continuously monitors inputs from the WIN and energizes the electric motor to move the locking bolt to the locked or unlocked position based upon that input. If the WIN indicates that the key present in the ignition lock cylinder is invalid, the locking bolt remains in the locked position. When the WIN indicates that a valid key is present in the ignition lock cylinder, the shaft lock module operates a motor to move the locking bolt to the unlocked position. However, to prevent inadvertent column locking due to a failure while the vehicle is being operated, the module cannot move the locking bolt from the unlocked position to the locked position as long as a key remains in the ignition lock cylinder. The shaft lock module receives ground at all times through a hard wired remote ground point. The module receives battery voltage to operate and to move the locking bolt in the unlocked direction on a B(+) circuit, and receives battery voltage to operate the locking bolt in the locked direction only when the key is removed from the ignition switch. These connections allow the module to remain operational, regardless of the ignition switch position. For added system security, the shaft lock module learns a unique Secret Key code from the WIN over the serial data bus upon initialization. This code is stored in the memory of the module and cannot be changed. Therefore, if the WIN requires service replacement, a new shaft lock module will also be required. Another security code, called a PIN, is used to gain access to the WIN Secured Access Mode. The Secured Access Mode is required during service to initialize a new shaft lock module. The shaft lock module is not available for separate service replacement. It is integral to the steering column so a complete column must be installed if the module is damaged or inoperative See: Service and Repair/Removal and Replacement/Steering Column - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Shaft Lock Module - Removal Steering Column Lock: Service and Repair Shaft Lock Module - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, insert a valid FOB with Integrated Key (FOBIK) into the ignition switch, then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the FOBIK in the ignition switch until service has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 1. Insert a FOB with Integrated Key (FOBIK) into the ignition switch to move the shaft lock module locking bolt to the unlocked position. Leave the FOBIK in the ignition switch while the shaft lock module service is being completed. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the instrument panel wire harness connector (3) from the shaft lock module (2) connector receptacle. 4. Remove the steering column from the vehicle. See: Service and Repair/Removal and Replacement/Steering Column Removal. 5. Depress the two spring clips that secure the shaft lock module to the mounting bracket on the steering column by inserting a suitable drift or punch into the release holes (1) on the upper surface of the bracket opposite the module. 6. While holding both of the spring clips depressed, slide the module toward the base of the column far enough to disengage the engagement tabs and slide tabs on the module from the slots and channels in the bracket. 7. Remove the module from the steering column bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Shaft Lock Module - Removal > Page 6598 Steering Column Lock: Service and Repair Shaft Lock Module - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Be certain that a valid FOB with Integrated Key (FOBIK) is still present in the ignition switch. Leave the FOBIK in the ignition switch while the shaft lock module service is being completed. 2. Align the engagement and slide tabs integral to the housing of the shaft lock module (1) with the slots and channels in the mounting bracket (3) on the steering column. 3. Slide the module toward the top of the column far enough for the spring clips (2) on the module to engage the bracket. 4. Reinstall the steering column into the vehicle. See: Service and Repair/Removal and Replacement/Steering Column - Installation. 5. Reconnect the instrument panel wire harness connector to the shaft lock module connector receptacle. 6. Reconnect the battery negative cable. NOTE: If the shaft lock module has been replaced with a new unit, the Wireless Ignition Node (WIN) MUST also be replaced. See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Service and Repair/Wireless Ignition Node Receiver - Removal . Also, a diagnostic scan tool MUST be used to initialize the new module before the vehicle can be operated. . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation Steering Gear: Description and Operation DESCRIPTION The steering gear (2) used is the rack-and-pinion type with power assist. It is mounted on the front suspension crossmember. The outer ends of the outer tie rods attach to the front (steering) knuckles. NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs with the steering gear, the complete steering gear needs to be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 6602 Steering Gear: Testing and Inspection POWER STEERING GEAR NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection/Component Tests and General Diagnostics OBJECTIONABLE HISS OR WHISTLE POSSIBLY CAUSED BY A NOISY STEERING GEAR 1. Check and adjust power steering fluid level in the reservoir as necessary. See: Service and Repair/Power Steering Fluid Level Checking 2. Start the vehicle and heat system by steering lock-to-lock 5 times with the engine running at 3000 rpm. Do not hold the gear against the stops for more than 5 seconds at a time. 3. Return the engine to idle speed. 4. Listen for the noise when turning the wheel slowly off center during a dry park maneuver. 5. Replace power steering gear if the hiss or whistle is present. See: Service and Repair/Steering Gear - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal Steering Gear: Service and Repair Steering Gear - Removal LEFT-HAND DRIVE NOTE: Before proceeding, See: Service Precautions . 1. Siphon out as much power steering fluid as possible from the reservoir. 2. Place the front wheels of vehicle (and steering wheel) in the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation while the intermediate shaft is disconnected. 3. Reposition the floor carpeting and sound deadening insulation to access the intermediate shaft coupling (1) at the base of the column. 4. Remove the intermediate shaft coupling bolt (2). 5. Separate the intermediate shaft coupling (1) from the steering gear pinion shaft (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6605 6. Release the clips securing the dash seal to the dash panel and push the seal away from the dash panel. 7. Raise and support the vehicle. See: Maintenance 8. On each side of the vehicle, remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 9. On each side of the gear, remove the nut (3) from the out tie rod end (6) at the knuckle (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6606 10. On each side of the gear, separate the outer tie rod end (1) from the knuckle (3) using Remover (2), Special Tool 9360. 11. If equipped, remove the engine belly pan. 12. Remove the rear engine mount through-bolt (1). 13. Remove the front engine mount through-bolt (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6607 14. Remove the screws (1) securing the power steering hose routing clamps (2) to the rear of the crossmember. 15. Unscrew the tube nut (2), then remove the return hose (1) at the steering gear. 16. Unscrew the tube nut (3), then remove the pressure hose (4) at the steering gear. NOTE: Before lowering the front suspension crossmember, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 17. Using a crayon or marker (2) that will not break the paint surface, mark the location of the front crossmember (1) on the body near each mounting bolt. Do not use any type of sharp instrument that will damage the underbody of the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6608 18. Support the crossmember (9) with a transmission jack. 19. Remove the four mounting bolts (6) securing the front crossmember (9) to the body. 20. Remove the mounting screws (8) securing the front crossmember reinforcement brackets (7) (one each side of vehicle) to the body (1). Remove the brackets. 21. Using the jack, slowly lower the crossmember approximately 3 inches (76 mm) (as measured at the rear crossmember mounts). Do not lower the crossmember more than necessary as the fore/aft crossmember is still attached to the radiator support and damage may occur. 22. Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2). Remove the shield. 23. Remove the two bolts (1) securing the steering gear (2) to the crossmember. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6609 24. Tip the steering gear pinion shaft (3) straight up and remove the dash seal (2) from the steering gear. 25. Slide the steering gear across the crossmember and out through left wheel opening. 26. If necessary, remove outer tie rods from inner tie rod threads. Count how many rotations it takes to remove each outer tie rod for installation reference. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6610 Steering Gear: Service and Repair Steering Gear - Installation LEFT-HAND DRIVE 1. If necessary, install the outer tie rods onto the inner tie rod threads. As the outer tie rods are installed, count out same number rotations as were counted on tie rod removal. This will get the toe setting somewhat close to specification before the vehicle is aligned at end of this procedure. Snug the tie rod jam nuts on both ends of gear. Tighten the tie rod jam nuts to specification while performing the wheel alignment at end of this procedure. 2. Carefully install the steering gear (1) through the left wheel opening using the reverse of how it was removed. Move it across the crossmember until centered. 3. Tip the steering gear pinion shaft (3) straight up and install the dash seal (2) matching it to the contour of the steering gear housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6611 4. Position the steering gear in mounted position on the crossmember. 5. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the gear mounting bolts to 100 Nm (74 ft. lbs.). 6. Install the heat shield (1) over the steering gear (2). Install the mounting screws and push-pins. Tighten the screws to 6 Nm (53 in. lbs.). 7. Center the power steering gear rack in its travel as necessary. NOTE: When installing the front suspension crossmember (1) it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost making wheel alignment more difficult. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6612 8. Slowly raise the crossmember (9) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. 9. Position the front crossmember reinforcement brackets (7) (one each side of vehicle) over the crossmember rear mounting bushings and install the mounting screws (8), but do not tighten at this time. 10. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 135 Nm (100 ft. lbs.). 11. Tighten the crossmember reinforcement bracket mounting screws (8) to 50 Nm (37 ft. lbs.). 12. Remove the transmission jack. 13. Install the pressure hose tube (4) at the gear. Tighten the tube nut (3) to 32 Nm (24 ft. lbs.). 14. Install the return hose tube (1) at the gear. Tighten the tube nut (2) to 32 Nm (24 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6613 15. Position the power steering hose routing clamps (2) on the crossmember. Install and tighten the screws to 8 Nm (71 in. lbs.). 16. Install the rear engine mount through-bolt (1). 17. Install the front engine mount through-bolt (1). See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator - Installation 18. If equipped, install the engine belly pan. NOTE: Prior to attaching the outer tie rod end to the knuckle, inspect the tie rod seal boot. If the seal boot is damaged, replace the outer tie Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6614 rod end. 19. On each side of the gear, install the outer tie rod end (6) into the hole in the knuckle (2) arm. Start a NEW tie rod mounting nut (3) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 85 Nm (63 ft. lbs.). 20. On each side of the vehicle, install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 21. Lower the vehicle. 22. Lift the dash seal into position and engage the retaining clips securing the dash seal to the dash panel. 23. Remove the steering wheel holder using care not to rotate the steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6615 24. Verify the front wheels of vehicle are in the STRAIGHT-AHEAD position. 25. Center the intermediate shaft coupling (1) over the steering gear pinion shaft (3), then slide the intermediate shaft onto the steering gear pinion shaft. 26. Install the intermediate shaft coupling bolt (2). Tighten the bolt to 42 Nm (31 ft. lbs.). 27. Position the sound deadening insulation and floor carpet back into place. 28. Fill and bleed the power steering system. See: Service and Repair/Steering - Power Steering System Bleeding 29. Check for fluid leaks. 30. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 6619 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6622 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C3 (Instrument Panel) 4 Way Connector C3 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6623 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 6624 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C8 (Steering Wheel) 6 Way Connector C8 - (STEERING WHEEL) 6 WAY MODULE-STEERING CONTROL - (STEERING WHEEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (1), control knob and control sleeve that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions and electrical connections are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the SCM through a jumper wire harness (5) directly to the right (wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is integral to the back of the switch housing and connects the SCM to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function switch must be replaced. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6627 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6628 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM). The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch (with integral Steering Control Module) - Right Multi-Function Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6629 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Page 6630 Steering Mounted Controls Communication Module: Testing and Inspection STEERING CONTROL MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the Steering Control Module (SCM) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or the electronic controls or communication between modules and other devices that provide some features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel See: Steering Wheel/Service and Repair/Removal. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM)See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6633 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6634 7. Disconnect the right switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6635 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6636 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6637 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal Steering Wheel: Service and Repair Removal REMOVAL WARNING: Do not place a non-deployed airbag face down on a hard surface. The airbag will propel into the air if accidentally deployed. Failure to follow this instruction may result in possible serious or fatal injury. - Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. This will disable the airbag system. Failure to follow this instruction may result in accidental airbag deployment and possible serious or fatal injury. - Allow the airbag system capacitor to discharge for two minutes before removing the steering wheel or any airbag system component. Failure to follow this instruction may result in accidental airbag deployment and possible serious or fatal injury. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove the driver airbag (3) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 4. Disconnect the wiring connector (2) at the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6642 5. While holding the steering wheel (2) firmly in place, remove the bolt (4) that secures the steering wheel to the steering column shaft (1). CAUTION: Do not bump or hammer on the steering wheel or steering column shaft when removing the steering wheel. 6. Install an appropriate wheel puller with hooked legs (1) on the steering wheel over the steering shaft. CAUTION: Do not attempt to rotate the clockspring rotor once the steering wheel is removed. The clockspring must remain centered in its travel to avoid overextending the clockspring inner parts, causing the clockspring to become inoperative. If removed and handled properly using the correct procedures, it should remain in the "centered" position. If there is any question as to whether the clockspring is in the "centered" position of travel, perform the clockspring centering procedure before installing the steering wheel See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures . 7. While holding the steering wheel firmly in the STRAIGHT-AHEAD position, remove the steering wheel from the steering column shaft splines using the wheel puller. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6643 Steering Wheel: Service and Repair Installation INSTALLATION 1. Confirm that: a. The front wheels are in the STRAIGHT-AHEAD position. b. The turn signal stalk is in the NEUTRAL position. CAUTION: Do not install the steering wheel onto the shaft of the steering column by driving it onto the shaft. 2. Align the wide mounting spline of the steering wheel (2) with the missing spline area of the steering column shaft (1) and push the wheel onto the shaft. Make sure the clockspring lines up with the back of the wheel and does not bind. 3. Install the steering wheel retaining bolt (4). Tighten the steering wheel retaining bolt to 50 Nm (37 ft. lbs.). 4. Connect the wiring connector (2) at the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6644 5. Install the driver airbag (3) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation. WARNING: Do not reconnect the battery without first performing the Airbag System Test procedure See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics . Failure to perform the Airbag System Test may result in accidental airbag deployment and serious or fatal injury. 6. Reconnect the battery using the Airbag System Test procedure See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics. 7. Verify vehicle and system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection TIE ROD Tie rod free-play can be measured using the following hand methods: OUTER TIE ROD 1. Raise and support the vehicle. See: Maintenance. 2. Remove the front wheels. See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 3. Install two standard wheel mounting nuts, flat side to rotor, diagonally opposite to each on the rotor. 4. Attach a magnetic dial indicator (2) to the inside or outside of the brake rotor, then align the dial indicator's contact pointer (1) with the direction of the stud axis and touch the outer tie rod. 5. Zero the dial indicator. (3) NOTE: When checking free-play, DO NOT rotate the tie rod. Just because a tie rod rotates easily does not mean that it is necessarily faulty. Using more than light hand pressure will result in a false reading. 6. Grasp the outer tie rod near the ball stud and attempt to move the tie rod straight up and down using light hand pressure. (Less than 10 lbs. of force.) 7. Measure and record any tie rod free-play movement. 8. Remove the magnetic dial indicator. 9. Remove the standard wheel mounting nuts from the two studs. If the free-play in the tie rod exceeds 0.05 mm (.002 in.), replace the outer tie rod. See: Service and Repair/Tie Rod End - Removal. If the free-play is less than 0.05 mm (.002 in.) at the outer tie rod check the inner tie rod for free-play. Refer to the following procedure. INNER TIE ROD Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 6649 NOTE: Always check and repair (if necessary) outer tie rod free-play before checking inner tie rod free-play. False results can otherwise be obtained. 1. Grasp the inner tie rod near the steering gear bellows and attempt to move the tie rod straight up and down. If any free-play is felt, replace the inner tie rod See: Service and Repair/Tie Rod End - Removal. 2. If no free-play is felt, install the front wheels. See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation 3. Remove support and lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal Tie Rod End: Service and Repair Tie Rod End - Removal Inner Tie Rod INNER TIE ROD 1. Remove the outer tie rod. See: 2. Remove the tie rod jam nut from the inner tie rod. 3. If servicing the right inner tie rod, remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2). Remove the heat shield from over the bellows. 4. Remove the clamp (3) securing the bellows (1) to the inner tie rod. 5. Remove the clamp (2) securing the bellows (1) to the steering gear body. 6. Remove the bellows. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6652 7. Remove the travel restrictor (3) from the inner tie rod (1). 8. Install an appropriate inner tie rod removal tool on the inner tie rod (1) hex. CAUTION: If the inner tie rod cannot be removed using the specified tools, do not use a hammer or heat to loosen. Damage to the steering gear will occur. Replace the entire steering gear. 9. Unthread and remove the inner tie rod (1) from the steering gear (2). Outer Tie Rod End OUTER TIE ROD END 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3) , then the tire and wheel assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6653 3. Loosen the tie rod jam nut. 4. Remove the nut (3) attaching the outer tie rod end (6) to the knuckle (2). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 5. Separate the outer tie rod end (1) from the knuckle (3) using Remover (2), Special Tool 9360. Remove the outer tie rod from the knuckle. NOTE: When unscrewing the outer tie rod from inner, count the number of revolutions to take it off. This action will aid in installation, getting the toe close to where it needs to be when setting the wheel alignment. 6. Remove the outer tie rod from the inner tie rod. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6654 Tie Rod End: Service and Repair Tie Rod End - Installation Inner Tie Rod INNER TIE ROD CAUTION: When installing the travel restrictor, be sure to use the same color and thickness travel restrictor as was removed. This action is necessary to properly set gear travel for the steering gear being serviced. Travel restrictor thickness can vary side-to-side on the steering gear. 1. Install the travel restrictor (1), flat side of teeth (2) facing out, on the inboard end of the inner tie rod ball joint. 2. Apply Mopar(R) Lock & Seal Adhesive or equivalent medium thread locker adhesive to the inboard end threads of the inner tie rod. 3. Install the inner tie rod (1) onto the gear (2) using an appropriate inner tie rod installation tool or crows foot wrench on the hex. Tighten the inner tie rod to 78 Nm, (58 ft. lbs.). 4. Loosely place a NEW clamp over the large end of the NEW bellows. 5. Slide the NEW bellows with clamp over the end of the inner tie rod and onto the gear body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6655 6. Push the small end of the bellows (2) past the groove (1) machined into the inner tie rod. 7. Apply a small amount of Mopar(R) Lubriplate or equivalent uniformly to the groove (1) in the inner tie rod shaft. This allows for toe adjustment without twisting the bellows. 8. Pull the small end of the bellows outward until the ridge inside the bellows engages the groove. 9. Install a NEW clamp (3) over the small end of the bellows (1). 10. Using crimping pliers (1), crimp the large clamp (2) securing the bellows to the gear body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6656 11. If servicing the right inner tie rod, position the heat shield (1) over the steering gear (2). Install mounting screws and push-pins. Tighten the screws to 6 Nm (53 in. lbs.). 12. Thread the tie rod jam nut onto the inner tie rod far enough to install the outer tie rod. 13. Install the outer tie rod. See: Outer Tie Rod End OUTER TIE ROD END 1. If it is not already installed, install the jam nut on the inner tie rod threads. Thread the jam nut down the inner tie rod far enough to allow for outer tie rod installation. 2. Thread the outer tie rod onto the inner tie rod approximately the same amount of revolutions as the original was installed. Do not tighten the jam nut at this time. 3. Install the outer tie rod end (6) into the hole in the knuckle (2) arm. Start a NEW tie rod mounting nut (3) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 85 Nm (63 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6657 4. Install the tire and wheel assembly (1)See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Lower the vehicle. 6. Adjust the front wheel toe setting. See: Alignment/Service and Repair. 7. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.) once wheel toe is set. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications The end play is acceptable if no more than 1.0 mm (0.039 in.) of end play is achieved back-to-back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 6662 Ball Joint: Testing and Inspection LOWER BALL JOINT 1. Raise the vehicle allowing the front suspension to hang. 2. Remove the tire and wheel assembly. 3. Using Dial Indicator C-3339A, or equivalent, attach the dial indicator mount to the knuckle and align the dial indicator's plunger with the direction of the stud axis, touching the end of the ball joint stud in the lower control arm. 4. Push up on the lower control arm and zero the dial indicator. NOTE: Use care when applying load to the knuckle as to avoid damaging the ball joint seal boot. 5. From the front of the vehicle, insert a pry bar between the knuckle and lower control arm, resting it on the lower control arm. Use lever principle to push the knuckle up from the lower control arm. Apply the load until the needle of the dial indicator no longer moves. 6. Record the ball joint movement. The end play is acceptable if no more than 1.0 mm (0.039 in.) of end play is achieved back-to-back. 7. Perform this procedure on each side of the vehicle as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation Ball Joint: Service and Repair Front Suspension Lower Ball Joint - Installation INSTALLATION 1. Install Installer (2), Special Tool 9964-1, and Installer (4), Special Tool 9964-2 on Remover/Installer (5), Special Tool 8441-1. Place a new ball joint (stem down) into Installer 9964-2. 2. Position the assembly onto the knuckle as shown, then hand tighten the screw-drive. 3. Using hand-tools, tighten the screw-drive forcing the ball joint (3) into the knuckle (1). Continue to install the ball joint until the flange on the ball joint comes to a stop against the bottom of the knuckle. 4. Loosen the screw-drive and remove the tools. 5. Install a NEW snap-ring into the groove in the ball joint using a drift punch. 6. Slide the hub and bearing in the knuckle (2) onto the splines of the half shaft outer C/V joint (1). 7. Insert the lower ball joint stud into the mounting hole in the lower control arm. 8. Install a NEW ball joint stud nut (4). Tighten the nut to 95 Nm (70 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6665 9. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 Nm (106 in. lbs.). 10. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 11. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 12. Clean all foreign matter from the threads of the half shaft outer C/V joint. 13. Install the hub nut (1) on the end of the half shaft (2) and snug it. 14. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (3) to 132 Nm (97 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6666 15. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6667 Ball Joint: Service and Repair Front Suspension Lower Ball Joint - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6668 5. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5). 6. Remove the screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle. 7. Remove the nut (4) attaching the lower ball joint to the lower control arm (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6669 8. Release the lower ball joint (5) from the lower control arm (1) using Remover (2) 9360. Do not lift the knuckle out of the lower control arm at this time. 9. Lift the knuckle (2) out of the lower control arm (5). NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 10. Pull the knuckle (2) off the axle half shaft (1) outer C/V joint splines and support the half shaft. 11. Through the access hole (1) in the knuckle, tap the ends of the snap-ring (2) with a drift punch and remove it from the ball joint. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6670 12. Install Remover (2) 9964-3, and Remover (4), Special Tool 9964-4 on Remover/Installer (5), Special Tool 8441-1. Place the tools over the ball joint (3) as shown, then hand tighten the screw-drive. 13. Using hand-tools, tighten the screw-drive forcing the ball joint (3) out of the knuckle (1). 14. Loosen the screw-drive and remove the tools and ball joint. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection Control Arm: Testing and Inspection LOWER CONTROL ARM Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm is serviced only as a complete component. Inspect both lower control arm isolator bushings for severe deterioration and replace the lower control arm as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal Control Arm: Service and Repair Front Lower Control Arm - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (4) attaching the lower ball joint to the lower control arm (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6676 4. Release the lower ball joint (3) from the lower control arm (1) using Remover (2) 9360. Do not lift the knuckle out of the lower control arm at this time. CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the knuckle outward at this point can separate the inner C/V joint on the half shaft thus damaging it. 5. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2). 6. Rotate the ends of the stabilizer bar (2) upward away from the lower control arm. 7. Remove the front bolt (1) attaching the lower control arm (3) to the front suspension crossmember. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6677 8. Remove the nut on the rear bolt (2) attaching the lower control arm (3) to the front suspension crossmember. Remove the bolt. 9. Remove the lower control arm (3) from the crossmember. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6678 Control Arm: Service and Repair Front Lower Control Arm - Installation INSTALLATION 1. Place the lower control arm (3) into the front suspension crossmember. 2. Insert the rear bolt (2) up through the crossmember and lower control arm (3). Install the nut on the top-end of the bolt, but do not tighten it at this time. 3. Install, but do not fully tighten, the front bolt (1) attaching the lower control arm (3) to the crossmember. 4. With no weight or obstruction on the lower control arm, tighten the lower control arm front mounting bolt (1) to 200 Nm (148 ft. lbs.). 5. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut to 145 Nm (107 ft. lbs.). 6. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 48 Nm (35 ft. lbs.). NOTE: If a new or cleaned lower control arm is being installed, it is important to have a film of general purpose grease around the ball joint mounting hole on the lower control arm to avoid any future corrosion issues. Make sure the grease does not get inside the ball joint mounting hole or on the ball joint stud during installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6679 7. Insert the lower ball joint stud into the mounting hole in the lower control arm (5). 8. Install a NEW ball joint stud nut (4). Tighten the nut to 95 Nm (70 ft. lbs.). 9. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Lower the vehicle. 11. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6680 Control Arm: Service and Repair Rear Upper Control Arm - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (3) and bolt (4) securing the upper control arm (5) to the knuckle. 4. Remove the nut (2) and bolt (1) securing the upper control arm (5) to the crossmember. 5. Remove the upper control arm (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6681 Control Arm: Service and Repair Rear Upper Control Arm - Installation INSTALLATION 1. Position the upper control arm (5) and install the bolt (1) and nut (2) securing the arm to the crossmember. Do not tighten at this time. 2. Install the bolt (4) and nut (3) securing the upper control arm (5) to the knuckle. Do not tighten at this time. 3. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the upper control arm mounting bolt nut at the crossmember to 105 Nm (77 ft. lbs.). 7. Tighten the upper control arm mounting bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 8. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6682 Control Arm: Service and Repair Front Lower Control Arm - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (4) attaching the lower ball joint to the lower control arm (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6683 4. Release the lower ball joint (3) from the lower control arm (1) using Remover (2) 9360. Do not lift the knuckle out of the lower control arm at this time. CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the knuckle outward at this point can separate the inner C/V joint on the half shaft thus damaging it. 5. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2). 6. Rotate the ends of the stabilizer bar (2) upward away from the lower control arm. 7. Remove the front bolt (1) attaching the lower control arm (3) to the front suspension crossmember. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6684 8. Remove the nut on the rear bolt (2) attaching the lower control arm (3) to the front suspension crossmember. Remove the bolt. 9. Remove the lower control arm (3) from the crossmember. Front Lower Control Arm - Installation INSTALLATION 1. Place the lower control arm (3) into the front suspension crossmember. 2. Insert the rear bolt (2) up through the crossmember and lower control arm (3). Install the nut on the top-end of the bolt, but do not tighten it at this time. 3. Install, but do not fully tighten, the front bolt (1) attaching the lower control arm (3) to the crossmember. 4. With no weight or obstruction on the lower control arm, tighten the lower control arm front mounting bolt (1) to 200 Nm (148 ft. lbs.). 5. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut to 145 Nm (107 ft. lbs.). 6. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 48 Nm (35 ft. lbs.). NOTE: If a new or cleaned lower control arm is being installed, it is important to have a film of general purpose grease around the ball joint mounting hole on the lower control arm to avoid any future corrosion issues. Make sure the grease does not get inside the ball joint mounting hole or on the ball joint stud during installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6685 7. Insert the lower ball joint stud into the mounting hole in the lower control arm (5). 8. Install a NEW ball joint stud nut (4). Tighten the nut to 95 Nm (70 ft. lbs.). 9. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Lower the vehicle. 11. Perform wheel alignment as necessary. See: Alignment/Service and Repair Rear Upper Control Arm - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6686 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (3) and bolt (4) securing the upper control arm (5) to the knuckle. 4. Remove the nut (2) and bolt (1) securing the upper control arm (5) to the crossmember. 5. Remove the upper control arm (5). Rear Upper Control Arm - Installation INSTALLATION 1. Position the upper control arm (5) and install the bolt (1) and nut (2) securing the arm to the crossmember. Do not tighten at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6687 2. Install the bolt (4) and nut (3) securing the upper control arm (5) to the knuckle. Do not tighten at this time. 3. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the upper control arm mounting bolt nut at the crossmember to 105 Nm (77 ft. lbs.). 7. Tighten the upper control arm mounting bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 8. Perform wheel alignment as necessary. See: Alignment/Service and Repair Rear Lower Control Arm - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6688 3. If equipped, while holding the stabilizer bar link lower stud stationary, remove the nut (3) securing the link (2) to the lower control arm (4). 4. If equipped with load-leveling shocks, support the lower shock (1) with a jack (2) using just enough force to allow easy removal of the lower shock mounting bolt in the following step. Lower the jack following bolt removal. 5. Remove the lower shock mounting nut (1) and bolt (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6689 6. Remove the nut (2) and bolt (7) securing the lower control arm (3) to the knuckle (1). 7. Remove the nut (4) and bolt (6) securing the lower control arm (3) to the rear crossmember (5). 8. Remove the lower control arm (3). Rear Lower Control Arm - Installation INSTALLATION 1. Position the lower control arm (3) and install the bolt (6) and nut (4) securing the lower control arm to the crossmember (5). Do not tighten at this time. 2. Install the bolt (7) and nut (2) securing the lower control arm (3) to the knuckle (1). Do not tighten at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6690 3. If equipped with load-leveling shocks, place a jack (2) against the lower shock eye and support the lower end of the shock assembly (1). Lift the shock assembly using the jack until the hole in the lower shock eye lines up with that in the lower control arm. 4. Install the mounting bolt (4) and nut (1) fastening the shock assembly (2) to the lower control arm (3). Do not tighten at this time. NOTE: When attaching a stabilizer bar link to the lower control arm it is important that the lower mounting stud be positioned properly. The lower mounting stud on the right side link needs to point toward the front of the vehicle when inserted through the lower control arm mounting flange. The left side link lower stud needs to point toward the rear of the vehicle. Otherwise the suspension geometry will not function properly. CAUTION: Before installing the nut in the following step, it is especially important to clean the threads and apply Mopar(R) Lock & Seal Adhesive or equivalent. 5. If equipped, attach the stabilizer bar link (2) to the lower control arm (4). Install the nut (3) and while holding the stabilizer bar link lower stud stationary, tighten the nut (2) to 48 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 6691 6. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 9. Tighten the lower control arm mounting bolt nut at the crossmember to 105 Nm (77 ft. lbs.). 10. Tighten the lower control arm mounting bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 11. Tighten the shock assembly lower mounting bolt nut to 99 Nm (73 ft. lbs.). 12. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise Rear Cross-Member: Customer Interest Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 6701 b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 6702 CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise Rear Cross-Member: All Technical Service Bulletins Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 6708 b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 6709 CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 6710 Rear Cross-Member: By Symptom Technical Service Bulletin # 02-004-08 Date: 080731 Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 6711 a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 6712 3. Remove the brackets. CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 02-004-08 Date: 080731 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 6713 Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 6714 SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 6715 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle (3) is a single casting with legs machined for attachment to the front strut assembly on the top and steering linkage on the trailing end. A ball joint is located on the bottom of the knuckle which attaches to the lower control arm. The knuckle also has two machined, drilled legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the hub and bearing (1). A shield (not shown in figure) is fastened to the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 6719 Front Steering Knuckle: Testing and Inspection KNUCKLE The front suspension knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the knuckle. Inspect the lower ball joint per the inspection procedure. The lower ball joint can be replaced separately from the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal Front Steering Knuckle: Service and Repair Front Steering Knuckle - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6722 5. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (5). 6. Remove the screw (1) fastening the wheel speed sensor head (2) to the knuckle (3). Pull the sensor head out of the knuckle. 7. Remove the nut (3) attaching the outer tie rod (6) to the knuckle (2). To do this it might be necessary to hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6723 8. Release the outer tie rod end (1) from the knuckle (3) using Remover (2), Special Tool 9360. 9. Remove the outer tie rod from the knuckle. 10. Remove the nut (4) attaching the lower ball joint to the lower control arm (5). 11. Release the lower ball joint (3) from the lower control arm (1) using Remover (2), Special Tool 9360. Do not lift the knuckle out of the lower control arm at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6724 CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method. 12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 14. Pull the knuckle (2) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6725 15. If required, remove the three screws (2) fastening the shield (3) to the knuckle (1). Remove the shield. 16. If required, remove the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). 17. If required, slide the hub and bearing (1) out of the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6726 Front Steering Knuckle: Service and Repair Front Steering Knuckle - Installation INSTALLATION 1. If required, install the hub and bearing (1) by sliding it into the knuckle. 2. If installing hub and bearing, install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 Nm (60 ft. lbs.). 3. If required, install the shield on the knuckle. Install and tighten the three mounting screws (2) to 10 Nm (89 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6727 4. Slide the hub and bearing in the knuckle (2) onto the splines of the half shaft outer C/V joint (1). 5. Insert the lower ball joint stud into the mounting hole in the lower control arm. 6. Install a NEW ball joint stud nut (4). Tighten the nut to 95 Nm (70 ft. lbs.). CAUTION: The strut clevis-to-knuckle bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step. 7. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5). 8. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 140 Nm (103 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6728 9. Install the outer tie rod (6) ball stud into the hole in the knuckle (2) arm. Start the tie rod end-to-knuckle nut (4) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 85 Nm (63 ft. lbs.). 10. Install the wheel speed sensor head (2) into the knuckle (3). Install the mounting screw (1) and tighten it to 12 Nm (106 in. lbs.). 11. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (5). 12. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6729 13. Clean all foreign matter from the threads of the half shaft outer C/V joint. 14. Install the hub nut (1) on the end of the half shaft (2) and snug it. 15. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (3) to 132 Nm (97 ft. lbs.). 16. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 17. Lower the vehicle. 18. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Rear Toe Link - Removal Rear Knuckle Alignment Link: Service and Repair Rear Toe Link - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance 2. Remove the mounting bolt (2) and nut securing the toe link (3) to the knuckle. 3. Mark the position of the cam bolt cam on the crossmember using a paint marker or crayon. Do not use any type marker that will scratch or damage the surface of the crossmember. 4. While holding the cam bolt (4) head stationary, loosen and remove the toe link mounting cam bolt nut (3) and washer (1). Remove the cam bolt. 5. Remove the toe link (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Rear Toe Link - Removal > Page 6734 Rear Knuckle Alignment Link: Service and Repair Rear Toe Link - Installation INSTALLATION CAUTION: When installing the cam bolt (4) and washer make sure the cams stay inside the abutments built into the crossmember. Failure to do so can damage the abutments and make toe adjustment difficult. 1. Position the toe link (2) and install the cam bolt (4) from the front through the crossmember and link. Match the cam on the bolt to the marks made during removal or position the top of the cam to the 12 O'clock position. 2. Install the cam washer (1) and nut (3) securing the toe link (2) to the crossmember. Do not tighten at this time. 3. Install the mounting bolt (2) and nut securing the link to the knuckle. To install the bolt it may be necessary to flex the trailing link at the body mount bushing inward or outward using an appropriate prying tool. Do not tighten at this time. 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the toe link mounting bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 7. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Rear Toe Link - Removal > Page 6735 8. Once rear toe is set, while holding the cam bolt (4) head stationary, tighten the toe link mounting cam bolt nut (3) to 100 Nm (74 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Rear Suspension Knuckle - Removal Spindle: Service and Repair Rear Suspension Knuckle - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the bolt (2) securing the brake tube routing bracket (1) to the knuckle. 4. Remove the brake rotor or brake drum, then the hub and bearing. See: Wheel Bearing/Service and Repair/Rear Hub and Bearing - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Rear Suspension Knuckle - Removal > Page 6740 5. Remove the three bolts (3) securing the knuckle (1) to the trailing link (2). 6. Remove the nut (3) and bolt securing the toe link to the knuckle (1). 7. Remove the nut (4) and bolt securing the lower control arm to the knuckle (1). 8. Remove the nut (2) and bolt securing the upper control arm to the knuckle (1). 9. Remove the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Rear Suspension Knuckle - Removal > Page 6741 Spindle: Service and Repair Rear Suspension Knuckle - Installation INSTALLATION 1. Position the knuckle (1) on the upper and lower control arm, and the toe link. 2. Install the bolt and nut (2) securing the upper control arm to the knuckle. Do not tighten the mounting bolt nut at this time. 3. Install the bolt and nut (4) securing the lower control arm to the knuckle. Do not tighten the mounting bolt nut at this time. 4. Install the bolt and nut (3) securing the toe link to the knuckle. Do not tighten the mounting bolt nut at this time. CAUTION: Before installing the bolts in the following step, it is especially important to clean the threads and apply Mopar(R) Lock & Seal Adhesive or equivalent. 5. Install the three bolts (3) securing the trailing link (2) to the knuckle (1). Be sure to include the parking brake cable routing clamp when installing the top mounting bolt. Tighten the mounting bolts to 60 Nm (44 ft. lbs.). 6. Install the hub and bearing, then the brake rotor and caliper. See: Wheel Bearing/Service and Repair/Rear Hub and Bearing - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Rear Suspension Knuckle - Removal > Page 6742 7. Position the brake tube routing bracket (1) at the knuckle and install the mounting screw. Tighten the screw to 15 Nm (11 ft. lbs.). 8. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access yet to be tightened mounting bolts and nuts. 11. Tighten the upper control arm bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 12. Tighten the lower control arm bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 13. Tighten the toe link mounting bolt nut at the knuckle to 105 Nm (77 ft. lbs.). 14. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal Stabilizer Link: Service and Repair Front Stabilizer Bar Link - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the strut (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6748 4. While holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2). 5. Remove the stabilizer bar link (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6749 Stabilizer Link: Service and Repair Front Stabilizer Bar Link - Installation INSTALLATION 1. Attach the stabilizer bar link (1) to the stabilizer bar (2). Install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nut to 48 Nm (35 ft. lbs.). 2. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the stabilizer bar link stud stationary. Tighten the nut to 48 Nm (35 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6750 3. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6751 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Bar Link - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance 2. While holding the stabilizer bar link lower stud stationary, remove the nut (3) securing the link (2) to the lower control arm (4). 3. While holding the stabilizer bar link upper stud stationary, remove the nut (5) securing the link (2) to the stabilizer bar (1). 4. Remove the stabilizer bar link (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6752 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Bar Link - Installation INSTALLATION CAUTION: Before installing the nuts in the following steps, it is especially important to clean the threads and apply Mopar(R) Lock & Seal Adhesive or equivalent. 1. Install the stabilizer link (2) upper stud in the end of the stabilizer bar (1) from the inboard side. Install the nut (5) on the upper stud and while holding the stabilizer link stud stationary, tighten the nut to 48 Nm (35 ft. lbs.). NOTE: When attaching a stabilizer bar link to the lower control arm it is important that the lower mounting stud be positioned properly. The lower mounting stud on the right side link needs to point toward the front of the vehicle when inserted through the lower control arm mounting flange. The left side link lower stud needs to point toward the rear of the vehicle. Otherwise the suspension geometry will not function properly. 2. Attach the stabilizer bar link (2) to the lower control arm (4). Install the nut (3) and while holding the stabilizer bar link lower stud stationary, tighten the nut (2) to 48 Nm (35 ft. lbs.). 3. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut Assembly - Description Suspension Strut / Shock Absorber: Description and Operation Front Suspension Strut Assembly Description DESCRIPTION A Macpherson type design strut assembly is used in place of the traditional front suspension upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two attaching bolts and nuts going through the strut clevis bracket and knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the three threaded studs on the strut assembly's upper mount. The strut assembly includes the following components: - Upper mount (2) - Bearing and upper spring seat (3) - Upper spring isolator (4) - Dust shield (5) - Jounce bumper (6) - Coil spring (7) - Lower spring isolator (8) - Strut (damper) (9) Each component is serviced by removing the strut assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut Assembly - Description > Page 6757 Suspension Strut / Shock Absorber: Description and Operation Front Suspension Strut Assembly Operation OPERATION The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut Assembly - Description > Page 6758 Suspension Strut / Shock Absorber: Description and Operation Rear Shock Absorber - Description DESCRIPTION A coil-over shock absorber assembly supports each side of the vehicle. The bottom of the shock assembly mounts to the lower control arm. The top of the shock assembly mounts to the body. The shock assembly includes the following major components: - Upper bushing (3) - Upper mounting bracket (4) - Sleeve (5) - Lower bushing (6) - Jounce bumper (8) - Dust shield (9) - Upper spring isolator (10) - Coil spring (11) - Lower spring isolator (12) - Shock absorber (damper) (13) Each component is serviced by removing the shock assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut Assembly Suspension Strut / Shock Absorber: Testing and Inspection Front Suspension Strut Assembly STRUT ASSEMBLY Inspect the strut assembly for the following conditions: - Inspect for a damaged or broken coil spring (7). - Inspect for a torn or damaged dust shield (5). - Inspect for torn or deteriorated spring isolators (4, 8). - Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end of the strut fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly. - Inspect the jounce bumper (6) for signs of damage or deterioration. - Inspect the clearance between the shock tower and the coil spring. Make sure no fasteners are protruding through the shock tower possibly contacting the coil spring and strut. Because of the minimum clearance in this area, installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt or other metal fastener be installed into the strut tower (1) to take the place of an original plastic clip. Also, do not drill holes into the front strut tower for the installation of any metal fasteners into the shock tower area indicated (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut Assembly > Page 6761 Suspension Strut / Shock Absorber: Testing and Inspection Rear Shock Absorber, Coil-Over SHOCK ABSORBER Inspect the shock absorber for damage and evidence of fluid running from the upper end of the fluid reservoir. (Actual leakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit). A slight amount of seepage between the shaft and shaft seal is not unusual and does not affect performance of the shock absorber. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Remove the engine appearance cover. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). 5. Raise and support the vehicle. See: Maintenance Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6764 6. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: If both strut assemblies are to be removed, mark the strut assemblies right or left and keep the parts separated to avoid mix-up. Not all parts of the strut assembly are interchangeable side-to-side. 7. Remove the screw (1) securing the flex hose (2) routing bracket to the strut (6). 8. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the strut (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Hold the bolts stationary in the knuckle while removing the nuts, then tap the bolts out using a pin punch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6765 9. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 10. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. 11. Lower the vehicle just enough to open the hood without allowing the tires to touch the floor. 12. Remove the three nuts (1) attaching the strut assembly (2) upper mount to the strut tower. 13. Remove the strut assembly (2) from the vehicle. 14. For disassembly, See: Overhaul/Front Suspension Strut Assembly - Disassembly. Installation INSTALLATION 1. Raise the strut assembly (2) into the strut tower, aligning the three studs on the strut assembly upper mount with the holes in strut tower. Install the three mounting nuts (1) on the studs. Tighten the three nuts to 55 Nm (41 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6766 CAUTION: The strut clevis-to-knuckle bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the knuckle. 2. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two attaching bolts (5). Install the nuts (2). While holding the bolts in place, tighten the nuts to 140 Nm (103 ft. lbs.). 3. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the stabilizer bar link stud stationary. Tighten the nut to 48 Nm (35 ft. lbs.). 4. Secure the flex hose (2) routing bracket to the strut (6) with the mounting screw (1). Tighten the mounting screw to 13 Nm (120 in. lbs.). 5. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6767 and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 8. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 9. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). 10. Install the engine appearance cover. With Third Row Seating WITH THIRD ROW SEATING NOTE: Before proceeding, See: Service Precautions/Vehicle Damage Warnings . 1. Access and remove the rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal 2. Move insulation out of the way to access the shock assembly upper mounting nuts. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6768 3. Remove the two nuts (1) securing the shock assembly to the body bracket (2). 4. Raise and support the vehicle. See: Maintenance 5. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 6. If equipped with load-leveling shocks, support the lower shock (1) with a jack (2) using just enough force to allow easy removal of the lower shock mounting bolt in the following step. Lower the jack following bolt removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6769 7. Remove the lower shock mounting nut (1) and bolt (4). 8. Lower the shock assembly (2) out of the body bracket and lift out over rear suspension. Without Third Row Seating WITHOUT THIRD ROW SEATING NOTE: Before proceeding, See: Service Precautions/Vehicle Damage Warnings . 1. Remove four nuts, remove load floor. 2. Open access panel by breaking perforations along panel, then folding panel upward. 3. Move insulation out of the way to access shock assembly upper mounting nuts. 4. Remove the two nuts (1) securing the shock assembly to the body bracket (2). 5. Raise and support the vehicle. See: Maintenance Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6770 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 7. If equipped with load-leveling shocks, support the lower shock (1) with a jack (2) using just enough force to allow easy removal of the lower shock mounting bolt in the following step. Lower the jack following bolt removal. 8. Remove the lower shock mounting nut (1) and bolt (4). 9. Lower the shock assembly (2) out of the body bracket and lift out over rear suspension. With Third Row Seating WITH THIRD ROW SEATING Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6771 NOTE: When installing the shock assembly into the body bracket in the following step, be sure to position the upper mounting bracket so that the angular formed side (as viewed from above) of the mounting bracket flange (1) is facing outboard of vehicle (opposite side of bracket is rounded). 1. Insert the lower end of the shock assembly down though the lower control arm from above just enough to clear the body with the upper mount, then lift it up, inserting the upper mounting studs (3) through the body bracket (2). 2. If equipped with load-leveling shocks, place a jack (2) against the lower shock eye and support the lower end of the shock assembly (1). Lift the shock assembly using the jack until the hole in the lower shock eye lines up with that in the lower control arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6772 3. Install the mounting bolt (4) and nut (1) fastening the shock assembly (2) to the lower control arm (3). Do not tighten at this time. 4. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Lower the vehicle. 6. Install the two nuts (1) on the studs (3) securing the shock assembly to the body bracket (2). Tighten the mounting nuts to 55 Nm (41 ft. lbs.). 7. Install the rear quarter trim panel and components removed to access it. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6773 8. Position the vehicle on an alignment rack/drive-on lift. Raise the lift as necessary to access the shock mounting bolt and nut. 9. Tighten the shock assembly lower mounting bolt nut (1) to 99 Nm (73 ft. lbs.). Without Third Row Seating WITHOUT THIRD ROW SEATING NOTE: When installing the shock assembly into the body bracket in the following step, be sure to position the upper mounting bracket so that the angular formed side (as viewed from above) of the mounting bracket flange (1) is facing outboard of vehicle (opposite side of bracket is rounded). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6774 1. Insert the lower end of the shock assembly down though the lower control arm from above just enough to clear the body with the upper mount, then lift it up, inserting the upper mounting studs (3) through the body bracket (2). 2. If equipped with load-leveling shocks, place a jack (2) against the lower shock eye and support the lower end of the shock assembly (1). Lift the shock assembly using the jack until the hole in the lower shock eye lines up with that in the lower control arm. 3. Install the mounting bolt (4) and nut (1) fastening the shock assembly (2) to the lower control arm (3). Do not tighten at this time. 4. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6775 6. Install the two nuts (1) on the studs (3) securing the shock assembly to the body bracket (2). Tighten the mounting nuts to 55 Nm (41 ft. lbs.). 7. Remove four nuts, remove load floor. 8. Fold the access panel back into place. 9. Install the load floor. 10. Position the vehicle on an alignment rack/drive-on lift. Raise the lift as necessary to access the shock mounting bolt and nut. 11. Tighten the shock assembly lower mounting bolt nut (1) to 99 Nm (73 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6776 Suspension Strut / Shock Absorber: Overhaul Front Suspension Strut Assembly - Disassembly DISASSEMBLY NOTE: The strut assembly must be removed from the vehicle for it to be disassembled and assembled. See: Removal and Replacement/Front Strut / Shock/Removal For the disassembly and assembly of the strut assembly, use strut spring compressor, teamPSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mount and bearing, before the strut rod nut is removed. 1. If both struts are being serviced at the same time, mark both the coil spring and strut assembly according to which side of the vehicle the strut is being removed from. 2. Position the strut assembly (2) in the strut coil spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. Position the strut clevis bracket (2) straight outward, away from the compressor. 3. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. 4. Once the spring is sufficiently compressed, install Strut Nut Wrench (2) 9362, on the strut rod nut. Next, install a deep socket (1) on the end of the strut rod. While holding the strut rod from turning, remove the nut using the strut nut wrench. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6777 5. Remove the clamp (if installed) from the bottom of the coil spring and remove the strut (damper) (9) out through the bottom of the coil spring. 6. Remove the lower spring isolator (8) from the strut seat. 7. remove the dust shield (5) and jounce bumper (6). 8. Remove the upper strut mount (2) from the top of the bearing and upper spring seat (3). 9. Remove the upper spring seat (3) and isolator (4) from the top of the coil spring (5). NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with 11. 10. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 11. Inspect the strut assembly components for the following and replace as necessary: - Inspect the strut (damper) (9) for shaft binding over the full stroke of the shaft. - Inspect the jounce bumper (6) for cracks and signs of deterioration. - Inspect the dust shield (5) for cracks and tears. - Check the upper mount (2) for cracks and distortion and its retaining studs for any sign of damage. - Check the bearing and upper spring seat (3) for any binding. - Inspect the upper and lower spring isolators (4, 8) for material deterioration and distortion. - Inspect the coil spring (7) for any sign of damage to the coating. NOTE: For reassembly, See: Front Suspension Strut Assembly - Assembly . Front Suspension Strut Assembly - Assembly ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with 3. NOTE: To determine the flat coil end of the coil spring for the following step, attempt to stand the coil spring on-end on a flat, level surface. If Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6778 the coil spring stands on end, the end on the flat surface is the flat coil end. If the coil spring falls over, the end on the flat surface is not the flat coil end. Stand the coil spring on the opposite end to verify. 1. Place the coil spring flat coil end upward (see above note) in the spring compressor following the manufacturer's instructions. Before compressing the spring, rotate the spring so the end of the bottom coil is at approximately the 9 o'clock position as viewed above (or to where the spring was when removed from the compressor). This action will allow the strut (damper) clevis bracket to be positioned outward, away from the compressor once installed. 2. Slowly compress the coil spring until enough room is available for strut assembly reassembly. 3. Install the bearing and upper spring seat (3), and isolator (4) on top of the coil spring (7). 4. Install the upper mount (2) on top of the bearing and upper spring seat (3). 5. Install the lower spring isolator (8) on the spring seat on the strut (damper) (9). 6. Slide the jounce bumper (6) and dust shield (5) onto the strut rod. 7. Install the strut up through the bottom of the coil spring and upper spring seat, mount, and bearing until the lower spring seat contacts the lower end of the coil spring. Rotate the strut as necessary until the end of the bottom coil (2) comes in contact with the stop (1) built into the lower spring isolator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6779 8. While holding the strut in position, install the nut (1) on the end of the strut rod. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. 9. Install Strut Nut Wrench (2) 9362, on the strut rod nut. Next, install a deep socket (1) on the end of the strut rod. While holding the strut rod from turning, tighten the strut rod nut to 60 Nm (44 ft. lbs.) using a torque wrench on the end of Strut Nut Wrench (2) 9362. 10. Slowly release the tension from the coil spring by backing off the compressor (1) drive completely. As the tension is relieved, make sure the upper mount and bearing align properly. Verify the upper mount does not bind when rotated. 11. Remove the strut assembly from the spring compressor. 12. Install the strut assembly on the vehicle. See: Removal and Replacement/Front Strut / Shock/Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6780 Assembly ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with 3. NOTE: To determine the flat coil end of the coil spring for the following step, attempt to stand the coil spring on end on a flat, level surface. If the coil spring stands on end, the end on the flat surface is the flat coil end. If the coil spring falls over, the end on the flat surface is not the flat coil end. Stand the coil spring on the opposite end to verify. 1. Place the coil spring flat coil end downward (see above note) in the spring compressor following the manufacturer's instructions. 2. Slowly compress the coil spring until enough room is available for shock assembly reassembly. 3. Assemble the bushings (3, 6) and sleeve (5) through the upper mounting bracket (4). NOTE: When installing the upper spring isolator on the upper mounting bracket in the following step, make sure the tab on the isolator is positioned toward the forward mounting stud on the mounting bracket. To determine the forward mounting stud on the mounting bracket, position the angular formed side (as viewed from above; opposite side of bracket is rounded) of the mounting bracket flange (1) toward you with the mounting studs pointing upwards. The stud to the left would be the forward mounting stud for a left rear shock assembly. The stud to the right would be the forward mounting stud for a right rear shock assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6781 4. If not already together, install the upper spring isolator (10) on the upper mounting bracket (4). Make sure the tab on the isolator is positioned toward the forward mounting stud on the mounting bracket (See above note). 5. Install the upper mounting bracket (4) on top of the coil spring (11) matching the step in the isolator to the end of the coil. 6. Install the lower spring isolator (12) on the spring seat of the shock absorber (13). 7. Slide the dust shield (9), jounce bumper (8) and washer (7) onto the shock rod. 8. Install the shock absorber (13) up through the bottom of the coil spring (11) and upper mounting bracket until the lower spring seat contacts the lower end of the coil spring. 9. While holding the shock absorber in position, install the washer (2) and nut (1) on the end of the shock rod. CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the shock internal bearings can occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6782 10. Install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod (1). While holding the shock rod from turning, tighten the nut (2) using a crows foot wrench and a torque wrench. Tighten the shock rod nut to 41 Nm (30 ft. lbs.). 11. Turn the upper mounting bracket or shock absorber as necessary until the mounting studs on the mounting bracket line up with the lower mounting bolt eyelet at the bottom of the shock absorber. 12. Slowly release the tension from the coil spring by backing off the compressor (1) drive completely. 13. Remove the shock assembly from the spring compressor. 14. Install the shock assembly on the vehicle. See: Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over - Installation Disassembly DISASSEMBLY NOTE: The shock assembly must be removed from the vehicle for it to be disassembled and assembled. See: Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over - Removal For the disassembly and assembly of the shock assembly, use Strut Spring Compressor, teamPSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: Do not remove the shock rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mounting bracket, before the shock rod nut is removed. 1. If both shocks are being serviced at the same time, mark both the coil spring and shock assembly according to which side of the vehicle the shock is being removed from. 2. Position the shock assembly (2) in the strut spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. 3. Compress the coil spring until all spring tension is removed from the upper mounting bracket and bushings. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6783 CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the shock internal bearings can occur. 4. Once the spring is sufficiently compressed, install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod (1). While holding the shock rod from turning, remove the nut (2) using a wrench. Remove the washer below the nut. 5. Remove the shock absorber (13) out through the bottom of the coil spring (11). The washer (7), jounce bumper (8), dust shield (9) and lower spring isolator (12) will come out with the shock. 6. Slide the washer (7), jounce bumper (8), and dust shield (9) from the shock rod. 7. Remove the lower spring isolator (12) from the shock spring seat. 8. Remove the upper mounting bracket (4), bushings (3, 6), sleeve (5) and upper spring isolator (10) from the top of the spring. 9. Remove the bushings (3, 6), sleeve (5) and upper spring isolator (10) from the upper mounting bracket (4). NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with 11. 10. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6784 11. Inspect the shock assembly components for the following and replace as necessary: - Inspect the shock absorber (damper) (13) for shaft binding over the full stroke of the shaft. - Inspect the jounce bumper (8) for cracks and signs of deterioration. - Inspect the dust shield (9) for cracks and tears. - Check the upper mounting bracket (4) for cracks and distortion and its retaining studs for any sign of damage. - Inspect the upper (3) and lower (6) bushings for material deterioration and signs of deterioration. Inspect the sleeve (5) for wear and distortion. - Inspect the upper (10) and lower (12) spring isolators for material deterioration and distortion. - Inspect the coil spring (11) for any sign of damage to the coating. NOTE: For reassembly, See: Rear Suspension Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal Trailing Arm: Service and Repair Rear Suspension Trailing Link - Removal REMOVAL 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the screw (3) securing the brake flex hose and tube bracket (4) to the trailing link. 4. Remove the screw (2) securing the wheel speed sensor routing clip (1) to the trailing link. 5. Remove the three bolts (3) securing the knuckle (1) to the trailing link (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 6789 6. Remove the two bolts (2) fastening the leading end of the trailing link (3) to the body (1). 7. Remove the trailing link. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 6790 Trailing Arm: Service and Repair Rear Suspension Trailing Link - Installation INSTALLATION CAUTION: Before installing the bolts in the following step, it is especially important to clean the threads and apply Mopar(R) Lock & Seal Adhesive or equivalent. 1. Position the trailing link (2) and install the three bolts (3) securing the trailing link to the knuckle (1). Be sure to include the parking brake cable routing clamp when installing the top mounting bolt. Tighten the mounting bolts to 60 Nm (44 ft. lbs.). 2. Position the forward end of the trailing link (3) on the body (1) and install the two mounting bolts (2). Do not tighten the bolts at this time. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 6791 3. Position the brake flex hose and tube bracket (4) on the trailing link and install the mounting screw (3). Tighten the screw to 23 Nm (17 ft. lbs.). 4. Attach the wheel speed sensor routing clip (1) to the trailing link using the mounting screw (2). 5. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access yet to be tightened mounting bolts. 8. Tighten the two mounting bolts fastening the leading end of the trailing link (3) to the body (1) to 110 Nm (81 ft. lbs.). 9. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel bearing grease ............................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The front wheel bearing and wheel hub of this vehicle are a one piece sealed unit or hub and bearing unit type assembly. The hub and bearing (1) is mounted to the knuckle using four mounting bolts (2) and to the axle half shaft using a retaining nut. The center of the hub and bearing is splined to match the outer joint of the axle half shaft. Each front hub and bearing has five wheel mounting studs on the hub flange for mounting the wheel to the vehicle. The wheel mounting studs are the only replaceable components of the hub and bearing. Otherwise, the hub and bearing is serviced as a complete assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 6797 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (1) is mounted to the rear knuckle. All vehicles have a magnetic encoder integrated into the rear hub and bearing for speed sense. The encoder works with the rear wheel speed sensor (2) to provide wheel speed signal. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the hub and bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 6800 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6803 5. Remove the four bolts (2) fastening the hub and bearing to the knuckle (3). 6. Slide the hub and bearing (1) off the half shaft and out of the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6804 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the hub and bearing (1) by sliding it over the half shaft and into the knuckle. 2. Install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 Nm (60 ft. lbs.). 3. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 4. Clean all foreign matter from the threads of the half shaft outer C/V joint. 5. Install the hub nut (1) on the end of the half shaft (2) and lightly tighten it. 6. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (1) to 132 Nm (97 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6805 7. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6806 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal ALL-WHEEL-DRIVE NOTE: Before proceeding, See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. This will also allow more room to access the hub and bearing mounting bolts in a later step. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6807 6. Remove two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle (3). 7. Remove the disc brake caliper and adapter bracket (2) as an assembly from the knuckle (3) and rotor. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 8. Remove any retaining clips, then slide the brake rotor (2) off the hub and bearing (1). CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 9. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 10. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6808 11. Remove the four bolts (1) securing the hub and bearing to the knuckle. 12. Remove the hub and bearing from the knuckle and half shaft (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6809 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation ALL-WHEEL-DRIVE 1. With the brake shield in place on the knuckle, slide the hub and bearing over the axle half shaft and position it on the knuckle. 2. Install the four bolts (1) securing the hub and bearing to the knuckle. Tighten the bolts to 105 Nm (77 ft. lbs.). CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 3. Pass the wheel speed sensor head (2) through the hole in the brake shield, then push it into the mounting hole in hub and bearing (1) and align the mounting screw hole. 4. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6810 5. Clean the rotor mounting face of the hub and bearing (1) to remove any dirt or corrosion. 6. Install the brake rotor (2) over the hub and bearing (1). CAUTION: If the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism. 7. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6811 8. Install the disc brake caliper and adapter bracket (2) over the knuckle and rotor as an assembly. 9. Install the two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle. Tighten the mounting bolts to 100 Nm (74 ft. lbs.). NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 10. Clean all foreign matter from the threads of the half shaft outer C/V joint. 11. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 12. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 13. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 14. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6812 15. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Check the brake fluid level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension Hub Nut................................................................................................................................................ .....................................................132 Nm (97 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 6818 Axle Nut: Specifications Rear Suspension Hub Nut................................................................................................................................................ ...................................................245 Nm (181 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair HOISTING Refer to Owner's Manual provided with vehicle for proper emergency jacking procedures. WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When the engine or rear suspension is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. Failure to follow these instructions may result in personal injury or death. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands. A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 6829 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 6830 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: Maintenance 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6833 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6834 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6835 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6836 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6843 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6844 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: Maintenance 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6847 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6848 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6849 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6850 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-002-10 > May > 10 > Wheels/Tire - Highway Speed Vibration/Shake Tires: Customer Interest Wheels/Tire - Highway Speed Vibration/Shake NUMBER: 22-002-10 GROUP: Wheels/Tires DATE: May O7, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-08, DATED APRIL 19, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF VEHICLE MODEL YEARS. SUBJECT: Vehicle Vibration / Shake At Highway Speed OVERVIEW: This bulletin provides information to diagnose vehicle vibration concerns. MODELS: 2009-**2010** (JC) Journey DISCUSSION: Tires used on the Journey models include nylon cap material as part of their construction. Tires that include Nylon can temporarily "flat spot" when vehicles are shipped by car hauler or rail and if vehicles are stored for an extended period. Immediately following delivery, some vehicles may exhibit a vibration / shake due to temporary tire flat-spotting. The vibration may be felt in the steering wheel and / or seat, and may be most noticeable at highway speeds, 60mph (96 kph). This may be misinterpreted as an out of balance tire. NOTE: Do not attempt to rebalance the wheel/tire assembly until the vehicle has been driven for an extended period (20 minutes or more) at highway speeds. If the tires are flat-spotted, the vehicle vibration will go away after the tires are warmed up, (normally 10 to 20 minutes of highway driving depending on outside temperatures). If highway driving doesn't resolve the vehicle vibration, follow the procedures found in DealerCONNECT > TechCONNECT > Group 22 - Tires and Wheels > Tire and Wheel Vibration. Replacing tires should only be done as a last resort after all appropriate wheel and tire diagnostics have been completed. U.S. dealers can contact the MOPAR tire program if assistance is needed with obtaining any tire. POLICY: Reimbursable within the provisions of the warranty. **TIME ALLOWANCE**: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-002-11 > Apr > 11 > Wheels/Tires - Alternative 19 Inch Tires Tires: All Technical Service Bulletins Wheels/Tires - Alternative 19 Inch Tires NUMBER: 22-002-11 GROUP: Tires and wheels DATE: April 02, 2011 SUBJECT: Alternative 19 Inch Tires OVERVIEW: This bulletin specifies alternative 19 tires that should be used if the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) is not available. MODELS: 2009-2010 (JC) Journey NOTE: This bulletin applies to vehicles sold in U.S. and Canada (sales code YAA and YAC) markets only. DISCUSSION: The following 19 tires can be used as aftermarket replacement tires for the 2009 and 2010 model year Dodge Journey in the event that the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) are not available. Approved Alternative Tires: NOTE: It is recommended to use these tires only as sets of four. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-002-10 > May > 10 > Wheels/Tire - Highway Speed Vibration/Shake Tires: All Technical Service Bulletins Wheels/Tire - Highway Speed Vibration/Shake NUMBER: 22-002-10 GROUP: Wheels/Tires DATE: May O7, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-08, DATED APRIL 19, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF VEHICLE MODEL YEARS. SUBJECT: Vehicle Vibration / Shake At Highway Speed OVERVIEW: This bulletin provides information to diagnose vehicle vibration concerns. MODELS: 2009-**2010** (JC) Journey DISCUSSION: Tires used on the Journey models include nylon cap material as part of their construction. Tires that include Nylon can temporarily "flat spot" when vehicles are shipped by car hauler or rail and if vehicles are stored for an extended period. Immediately following delivery, some vehicles may exhibit a vibration / shake due to temporary tire flat-spotting. The vibration may be felt in the steering wheel and / or seat, and may be most noticeable at highway speeds, 60mph (96 kph). This may be misinterpreted as an out of balance tire. NOTE: Do not attempt to rebalance the wheel/tire assembly until the vehicle has been driven for an extended period (20 minutes or more) at highway speeds. If the tires are flat-spotted, the vehicle vibration will go away after the tires are warmed up, (normally 10 to 20 minutes of highway driving depending on outside temperatures). If highway driving doesn't resolve the vehicle vibration, follow the procedures found in DealerCONNECT > TechCONNECT > Group 22 - Tires and Wheels > Tire and Wheel Vibration. Replacing tires should only be done as a last resort after all appropriate wheel and tire diagnostics have been completed. U.S. dealers can contact the MOPAR tire program if assistance is needed with obtaining any tire. POLICY: Reimbursable within the provisions of the warranty. **TIME ALLOWANCE**: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 22-002-11 > Apr > 11 > Wheels/Tires - Alternative 19 Inch Tires Tires: All Technical Service Bulletins Wheels/Tires - Alternative 19 Inch Tires NUMBER: 22-002-11 GROUP: Tires and wheels DATE: April 02, 2011 SUBJECT: Alternative 19 Inch Tires OVERVIEW: This bulletin specifies alternative 19 tires that should be used if the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) is not available. MODELS: 2009-2010 (JC) Journey NOTE: This bulletin applies to vehicles sold in U.S. and Canada (sales code YAA and YAC) markets only. DISCUSSION: The following 19 tires can be used as aftermarket replacement tires for the 2009 and 2010 model year Dodge Journey in the event that the Khumo Solus KH16 P225/55R19 991 All Season (U.S. and Canada Markets Only) are not available. Approved Alternative Tires: NOTE: It is recommended to use these tires only as sets of four. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 6873 Tires: Specifications FASTENER TORQUE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires Tires: Description and Operation Tires TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval on Tire Rotation. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Tire type, size, load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the Tire Identification chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An All Season type tire will also have either M + S, M AND S, or M - S (indicating mud and snow traction) imprinted on the side wall. An Extra or Light Load marking "XL" or "LL" may also be listed on the sidewall. The absence of an "XL" or "LL" marking infers a standard load tire. TIRE IDENTIFICATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6876 NOTE: * Height (2) ÷ Width (1) = Aspect Ratio. NOTE: ** Consult the tire manufacturer regarding any questions on tire specifications or capabilities. TIRE CHAINS Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6877 Tires: Description and Operation Spare Tire SPARE TIRE A compact (temporary) spare tire and wheel assembly is standard equipment on this vehicle. A full-size spare is available on some models. Export vehicles are equipped with the TIREFIT tire repair kit as standard equipment in place of a spare tire. It is to be used to repair small punctures in the tire as necessary. A compact spare tire is optional. The compact spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the compact spare tire. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6878 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. WARNING: In order to maintain the speed capability of the vehicle, replacement tires must have speed ratings equal to or higher than those fitted to the vehicle as original equipment. If tires with lower speed ratings are fitted, the vehicle's handling may be affected and the speed capability of the vehicle may be lowered to the maximum speed capability of the replacement tires. To avoid an accident resulting in severe or fatal injury, consult the tire manufacturer in regards to maximum speed ratings. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 6881 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators will appear as a 13 mm (1/2 in.) band (3). Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRE CLEANING Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire And Loading Information Label provided with the vehicle (usually on the driver's door opening (B-pillar) or rear shutface of driver's door). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: Over or Under inflated tires can affect vehicle handling. The tire can fail suddenly, resulting in loss of vehicle control. Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6884 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks (1). Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEED OPERATION Refer to the vehicle's Owners Manual Package. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6885 Tires: Removal and Replacement TIRE LEAK REPAIRING For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the five wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 6890 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6891 Wheels: Specifications SPECIFICATIONS BASE WHEEL TORQUE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6892 Wheels: Description and Operation DESCRIPTION All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps (2). In case of air loss, these raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire forces the tire bead over these raised sections into place. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6893 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Chrysler LLC does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit (93 degrees Celsius). - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6894 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire AND Wheel Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: - Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel bearing grease ............................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The front wheel bearing and wheel hub of this vehicle are a one piece sealed unit or hub and bearing unit type assembly. The hub and bearing (1) is mounted to the knuckle using four mounting bolts (2) and to the axle half shaft using a retaining nut. The center of the hub and bearing is splined to match the outer joint of the axle half shaft. Each front hub and bearing has five wheel mounting studs on the hub flange for mounting the wheel to the vehicle. The wheel mounting studs are the only replaceable components of the hub and bearing. Otherwise, the hub and bearing is serviced as a complete assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 6900 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (1) is mounted to the rear knuckle. All vehicles have a magnetic encoder integrated into the rear hub and bearing for speed sense. The encoder works with the rear wheel speed sensor (2) to provide wheel speed signal. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub and bearing. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the hub and bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 6903 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Suspension/Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2). 4. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6906 5. Remove the four bolts (2) fastening the hub and bearing to the knuckle (3). 6. Slide the hub and bearing (1) off the half shaft and out of the knuckle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6907 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the hub and bearing (1) by sliding it over the half shaft and into the knuckle. 2. Install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 Nm (60 ft. lbs.). 3. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 4. Clean all foreign matter from the threads of the half shaft outer C/V joint. 5. Install the hub nut (1) on the end of the half shaft (2) and lightly tighten it. 6. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (1) to 132 Nm (97 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6908 7. Install the tire and wheel assembly (1) See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6909 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal ALL-WHEEL-DRIVE NOTE: Before proceeding, See: Suspension/Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing. This will also allow more room to access the hub and bearing mounting bolts in a later step. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before removal by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6910 6. Remove two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle (3). 7. Remove the disc brake caliper and adapter bracket (2) as an assembly from the knuckle (3) and rotor. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 8. Remove any retaining clips, then slide the brake rotor (2) off the hub and bearing (1). CAUTION: Prior to removal, clean area around sensor head to help prevent contaminants from entering bearing when sensor head is removed. 9. Remove the screw (3) fastening the speed sensor head (2) to the hub and bearing (1). 10. Remove the wheel speed sensor head (2) from the hub and bearing (1), then pass it through the brake shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6911 11. Remove the four bolts (1) securing the hub and bearing to the knuckle. 12. Remove the hub and bearing from the knuckle and half shaft (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6912 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation ALL-WHEEL-DRIVE 1. With the brake shield in place on the knuckle, slide the hub and bearing over the axle half shaft and position it on the knuckle. 2. Install the four bolts (1) securing the hub and bearing to the knuckle. Tighten the bolts to 105 Nm (77 ft. lbs.). CAUTION: Ensure that sensor mounting surface on bearing is clean before sensor installation. 3. Pass the wheel speed sensor head (2) through the hole in the brake shield, then push it into the mounting hole in hub and bearing (1) and align the mounting screw hole. 4. Install a NEW mounting screw (2). Tighten the mounting screw to 6 Nm (55 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6913 5. Clean the rotor mounting face of the hub and bearing (1) to remove any dirt or corrosion. 6. Install the brake rotor (2) over the hub and bearing (1). CAUTION: If the brake rotor or brake pads are being replaced, the rear caliper piston must be seated (bottomed) to compensate for the new brake rotor or lining. Because the parking brake self-adjuster mechanism is attached to the piston, a special seating method is required. The only acceptable method is by rotating the piston back into the bore using Retractor, Special Tool 8807, as described below. Any other seating method will damage the self-adjuster mechanism. 7. If necessary, seat (bottom) the caliper piston in the bore as follows: a. Assemble a 3/8 in. drive ratchet handle and an extension (3). b. Insert the extension through Special Tool 8807-1 (2). c. Place Special Tool 8807-2 (1) on the end of the extension. d. Insert lugs on Special Tool 8807-2 into notches in face of caliper piston (5). e. Thread the screw drive on 8807-1 down until it contacts the top of 8807-2 which is against the caliper piston. Do not over tighten the screw-drive. Damage to the piston can occur. f. Turn 8807-2 with the ratchet, rotating the piston in a clockwise direction until fully seated (bottomed) in the bore. It may be necessary to turn 8807-1 with 8807-2 to start the process of piston retraction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6914 8. Install the disc brake caliper and adapter bracket (2) over the knuckle and rotor as an assembly. 9. Install the two bolts (1) securing the disc brake caliper and adapter bracket (2) to the knuckle. Tighten the mounting bolts to 100 Nm (74 ft. lbs.). NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed. 10. Clean all foreign matter from the threads of the half shaft outer C/V joint. 11. Install the washer (4) and hub nut (3) on the end of the half shaft and snug it. 12. While a helper applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.). 13. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches in the nut do not line up with the hole in the half shaft, continue to tighten the nut until they do. Do not loosen the nut. 14. Wrap the cotter pin (2) ends tightly around the lock nut. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6915 15. Install tire and wheel assembly (1) See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 16. Lower the vehicle. 17. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Check the brake fluid level. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal Wheel Cover: Service and Repair Wheel Cover - Removal REMOVAL 1. Raise and support the vehicle so that tire and wheel assembly clears ground level. See: Maintenance CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. It is held on by the wheel mounting nuts. 2. Remove the five wheel mounting (lug) nuts (3) from the wheel studs. While removing the nuts, hold the wheel cover (2) in place so it doesn't fall off when the last nut is removed. 3. Remove the wheel cover (2) using care not to let the tire and wheel assembly (1) fall off the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal > Page 6920 Wheel Cover: Service and Repair Wheel Cover - Installation INSTALLATION WARNING: Installing wheels without good metal-to-metal contact with the mounting surface could cause loosening of the wheel mounting (lug) nuts. This could adversely affect the safety and handling of the vehicle. NOTE: Never use oil or grease on studs or wheel mounting (lug) nuts. 1. With the tire and wheel assembly (1) positioned on the wheel studs without the wheel mounting (lug) nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover over the studs. NOTE: Always use the original (OEM) style wheel mounting (lug) nuts. Do not use replacement parts of lesser quality or substitute design. 2. Install and lightly snug all five wheel mounting (lug) nuts (3) Do not tighten at this time. 3. Lower the vehicle. 4. Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of 135 Nm (100 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension Hub Nut................................................................................................................................................ .....................................................132 Nm (97 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 6926 Axle Nut: Specifications Rear Suspension Hub Nut................................................................................................................................................ ...................................................245 Nm (181 ft. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut.................................................................................................................... ...................................................135 Nm (100 ft.lbs) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal Wheel Fastener: Service and Repair Wheel Stud - Removal Front REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 2. Install Remover 8677 (3) on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Rear REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove rear brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 6932 2. Install Remover (3), Special Tool 8677, on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 6933 Wheel Fastener: Service and Repair Wheel Stud - Installation Front INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation Rear INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 6934 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator Air Door Actuator / Motor: Locations Left Blend Door Actuator Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6941 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6942 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6943 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6944 Air Door Actuator / Motor: Locations Mode Door Actuator Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6945 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6946 Air Door Actuator / Motor: Locations Right Blend Door Actuator Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6947 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6948 Air Door Actuator / Motor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6949 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6950 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6951 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6952 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6953 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6954 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6955 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6956 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 6957 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way Air Door Actuator / Motor: Diagrams Left Blend Door Actuator (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-BLEND DOOR-LEFT - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6960 Air Door Actuator / Motor: Diagrams Rear Blend Door Actuator (3 Zone HVAC) (Rear HVAC Jumper) 6 Way Connector (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY ACTUATOR-BLEND DOOR-REAR (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6961 Air Door Actuator / Motor: Diagrams Right Blend Door Actuator (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-BLEND DOOR-RIGHT - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6962 Air Door Actuator / Motor: Diagrams Rear Mode Door Actuator (3 Zone HVAC) (Rear HVAC Jumper) 6 Way Connector (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY ACTUATOR-MODE DOOR-REAR (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6963 Air Door Actuator / Motor: Diagrams Left Blend Door Actuator (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-BLEND DOOR-LEFT - (INSTRUMENT PANEL) 6 WAY Rear Blend Door Actuator (3 Zone HVAC) (Rear HVAC Jumper) 6 Way Connector (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6964 ACTUATOR-BLEND DOOR-REAR (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY Right Blend Door Actuator (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-BLEND DOOR-RIGHT - (INSTRUMENT PANEL) 6 WAY Rear Mode Door Actuator (3 Zone HVAC) (Rear HVAC Jumper) 6 Way Connector (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6965 ACTUATOR-MODE DOOR-REAR (3 ZONE HVAC) - (REAR HVAC JUMPER) 6 WAY Recirculation Door Actuator (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-RECIRCULATION DOOR - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (Instrument Panel) 6 Way > Page 6966 Mode Door Actuator (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-MODE DOOR - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description Air Door Actuator / Motor: Description and Operation Blend Door Actuator - Description Front DESCRIPTION The blend door actuators (1) for the front heating-A/C system are reversible, 12-volt direct current (DC) servo motors. Models with the front single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models with the front dual zone heating-A/C system have dual blend-air doors, which are controlled by two blend door actuators. The blend door actuator for the single zone heating-A/C system is located on the driver side front HVAC air distribution housing. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, which is mechanically connected to only the driver side blend-air door. A second separate blend door actuator is also located on the passenger side of the front air distribution housing which is mechanically connected to only the passenger side blend-air door. The blend door actuators are contained within a black molded plastic housing with an integral wire connector receptacle (2). An output shaft with splines (3) connect the blend door actuators to the blend door linkage. Three integral mounting tabs (4) allow the actuators to be secured to the air distribution housing. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The blend door actuators are interchangeable with the actuators for the recirculation and mode-air doors. Rear DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6969 The blend door actuator (1) for the rear heating-A/C system is a reversible, 12 volt direct current (DC), servo motor. The rear blend door actuator is located on the outboard side of the rear heater-A/C housing. The rear blend door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with splines (3) connect it to the rear blend-air door and three integral mounting tabs (4) allow the actuator to be secured to the rear heater-A/C housing. The blend door actuator does not require mechanical indexing to the blend door linkage, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blend door actuator is interchangeable with the actuator for the rear mode-air door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6970 Air Door Actuator / Motor: Description and Operation Blend Door Actuator - Operation Front OPERATION The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code(DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blend door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear blend door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear blend door actuator can move the rear blend-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear blend-air door moves in the opposite direction. When the front A/C-heater control makes the voltage to both connections high or both connections low, the rear blend-air door stops and will not move. The front A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear blend door actuator and the rear blend-air door. The front A/C-heater control learns the rear blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear blend door actuator circuits. The rear blend door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blend door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6971 Air Door Actuator / Motor: Description and Operation Mode Door Actuator - Description Front DESCRIPTION The mode door actuator (1) for the heating-A/C system is a reversible, 12-volt Direct Current (DC) servo motor, which is mechanically connected to the mode-air doors. The mode door actuator is located on the right side of the HVAC air distribution housing. The mode door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2). An output shaft with splines (3) connect it to mode door linkage and integral mounting tabs (4) allow the actuator to be secured to the air distribution housing. The mode door actuator does not require mechanical indexing to the mode-air doors, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The mode door actuator is interchangeable with the actuators for the recirculation and blend-air doors. Rear DESCRIPTION The mode door actuator (1) for the rear heater-A/C system is a reversible, 12 volt direct current (DC), servo motor. The rear mode door actuator is located on the outboard side of the rear heater-A/C housing. The rear mode door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6972 splines (3) connect it to the rear mode-air door and three integral mounting tabs (4) allow the actuator to be secured to the rear heater-A/C housing. The mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The rear mode door actuator is interchangeable with the actuator for the rear blend-air door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6973 Air Door Actuator / Motor: Description and Operation Mode Door Actuator - Operation Front OPERATION The mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the instrument panel wire harness. The mode door actuator can move the mode-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door moves in the opposite direction. Once the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the mode door actuator and the mode-air door. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The mode door actuator cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Rear OPERATION The rear mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear mode door actuator can move the rear mode-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear mode-air door moves in the opposite direction. When the front A/C-heater control makes the voltage to both connections high or both connections low, the rear mode-air door stops and will not move. The front A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear mode door actuator and the rear mode-air door. The front A/C-heater control learns the rear mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear mode door actuator circuits. The rear mode door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear mode door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6974 Air Door Actuator / Motor: Description and Operation Front DESCRIPTION The blend door actuators (1) for the front heating-A/C system are reversible, 12-volt direct current (DC) servo motors. Models with the front single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models with the front dual zone heating-A/C system have dual blend-air doors, which are controlled by two blend door actuators. The blend door actuator for the single zone heating-A/C system is located on the driver side front HVAC air distribution housing. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, which is mechanically connected to only the driver side blend-air door. A second separate blend door actuator is also located on the passenger side of the front air distribution housing which is mechanically connected to only the passenger side blend-air door. The blend door actuators are contained within a black molded plastic housing with an integral wire connector receptacle (2). An output shaft with splines (3) connect the blend door actuators to the blend door linkage. Three integral mounting tabs (4) allow the actuators to be secured to the air distribution housing. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The blend door actuators are interchangeable with the actuators for the recirculation and mode-air doors. Rear DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6975 The blend door actuator (1) for the rear heating-A/C system is a reversible, 12 volt direct current (DC), servo motor. The rear blend door actuator is located on the outboard side of the rear heater-A/C housing. The rear blend door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with splines (3) connect it to the rear blend-air door and three integral mounting tabs (4) allow the actuator to be secured to the rear heater-A/C housing. The blend door actuator does not require mechanical indexing to the blend door linkage, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blend door actuator is interchangeable with the actuator for the rear mode-air door. Front OPERATION The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code(DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blend door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear blend door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear blend door actuator can move the rear blend-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear blend-air door moves in the opposite direction. When the front A/C-heater control makes the voltage to both connections high or both connections low, the rear blend-air door stops and will not move. The front A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear blend door actuator and the rear blend-air door. The front A/C-heater control learns the rear blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear blend door actuator circuits. The rear blend door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6976 The rear blend door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Front DESCRIPTION The mode door actuator (1) for the heating-A/C system is a reversible, 12-volt Direct Current (DC) servo motor, which is mechanically connected to the mode-air doors. The mode door actuator is located on the right side of the HVAC air distribution housing. The mode door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2). An output shaft with splines (3) connect it to mode door linkage and integral mounting tabs (4) allow the actuator to be secured to the air distribution housing. The mode door actuator does not require mechanical indexing to the mode-air doors, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The mode door actuator is interchangeable with the actuators for the recirculation and blend-air doors. Rear DESCRIPTION The mode door actuator (1) for the rear heater-A/C system is a reversible, 12 volt direct current (DC), servo motor. The rear mode door actuator is located on the outboard side of the rear heater-A/C housing. The rear mode door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with splines (3) connect it to the rear mode-air door and three integral mounting tabs (4) allow the actuator to be secured to the rear heater-A/C housing. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6977 mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The rear mode door actuator is interchangeable with the actuator for the rear blend-air door. Front OPERATION The mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the instrument panel wire harness. The mode door actuator can move the mode-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door moves in the opposite direction. Once the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the mode door actuator and the mode-air door. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The mode door actuator cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Rear OPERATION The rear mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear mode door actuator can move the rear mode-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear mode-air door moves in the opposite direction. When the front A/C-heater control makes the voltage to both connections high or both connections low, the rear mode-air door stops and will not move. The front A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear mode door actuator and the rear mode-air door. The front A/C-heater control learns the rear mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear mode door actuator circuits. The rear mode door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear mode door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Recirculation Door Actuator - Description DESCRIPTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 6978 The recirculation door actuator (1) is a reversible, 12 volt direct current (DC) servo motor, which is connected directly to the pivot shaft lever of the recirculation-air door. The recirculation door actuator is located on the right side of the HVAC air inlet housing. The recirculation door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with splines (3) connect it to the recirculation door and three integral mounting tabs (4) allow the actuator to be secured to the air inlet housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The recirculation door actuator is interchangeable with the actuators for the blend and mode-air doors. Recirculation Door Actuator - Operation OPERATION The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the instrument panel wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the recirculation-air door moves in the opposite direction. Once the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The recirculation door actuator cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal Air Door Actuator / Motor: Service and Repair Blend Door Actuator - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. NOTE: LHD model shown in illustrations. SINGLE ZONE/DUAL ZONE LEFT SIDE 1. Disconnect and isolate the negative battery cable. 2. On RHD models, if equipped, remove the silencer from underneath the passenger side of the instrument panel. 3. On RHD models, remove the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 4. Disconnect the wire harness connector (1) from the blend door actuator (2) located on the left side of the HVAC air distribution housing (3). 5. Remove the two screws (4) that secure the blend door actuator to the air distribution housing and remove the actuator. DUAL ZONE RIGHT SIDE 1. Disconnect and isolate the negative battery cable. 2. On LHD models, if equipped, remove the silencer from underneath the passenger side of the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6981 3. On LHD models, remove the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 4. Remove the front floor distribution duct from the right side of the air distribution housing See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. 5. Remove the screws (2) that secure the blend door actuator (1) to the right side of the air distribution housing (4) and remove the actuator from the housing. 6. Disconnect the wire harness connector (3) from the blend door actuator and remove the actuator from the vehicle. Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove rear heater-A/C housing (4) and place it on a workbench . 3. Disconnect the wire harness connector (3) from the rear blend door actuator (2) located on the outboard side of the rear heater-A/C housing. 4. Remove the two screws (1) that secure the rear blend door actuator to the rear heater-A/C housing and remove the actuator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6982 Air Door Actuator / Motor: Service and Repair Blend Door Actuator - Installation Front INSTALLATION NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. NOTE: LHD model shown in illustrations. SINGLE ZONE/DUAL ZONE LEFT SIDE 1. Position the blend door actuator (2) onto the left side of the HVAC air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. 2. Install the two screws (4) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the wire harness connector (1) to the blend door actuator. 4. On RHD models, install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. 5. On RHD models, if equipped, install the silencer underneath the instrument panel. 6. Reconnect the negative battery cable. 7. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. DUAL ZONE RIGHT SIDE 1. Position the blend door actuator (1) to the right side of the HVAC air distribution housing (4) and connect the wire harness connector (3) to the actuator. 2. Install the blend door actuator onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator with the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6983 blend door linkage. 3. Install the two screws (2) that secure the blend door actuator to the air distribution housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 4. Install the right front floor distribution duct onto the air distribution housing See: Air Duct/Service and Repair/Floor Distribution Duct Installation. 5. On LHD models, install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. 6. On LHD models, if equipped, install the silencer underneath the instrument panel. 7. Reconnect the negative battery cable. 8. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION 1. Position the rear blend door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear blend-air door pivot shaft (2). 2. Install the two screws (1) that secure the rear blend door actuator (2) to the rear heater-A/C housing (4). Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (3) to the rear blend door actuator. 4. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6984 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 3. Remove the screws (1) that secure the mode door actuator (4) to the bracket (5) located on the right side of the HVAC air distribution housing (2). 4. Disconnect the wire harness connector (3) from the mode door actuator and remove the actuator. Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove rear heater-A/C housing (3) and place it on a workbench . 3. Disconnect the wire harness connector (4) from the rear mode door actuator (2) located on the outboard side of the rear heater-A/C housing. 4. Remove the two screws (1) that secure the rear mode door actuator to rear heater-A/C housing and remove the actuator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6985 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Installation Front INSTALLATION 1. Position the mode door actuator (4) onto the bracket (5) located on the right side of the HVAC air distribution housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode air door linkage. 2. Install the screws (1) that secure the mode door actuator to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the wire harness connector (3) to the mode door actuator. 4. Install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION 1. Position the rear mode door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear mode-air door pivot shaft (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6986 2. Install the two screws (1) that secure the rear mode door actuator (2) to the rear heater-A/C housing (3). Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (4) to the rear mode door actuator. 4. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6987 Air Door Actuator / Motor: Service and Repair Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. NOTE: LHD model shown in illustrations. SINGLE ZONE/DUAL ZONE LEFT SIDE 1. Disconnect and isolate the negative battery cable. 2. On RHD models, if equipped, remove the silencer from underneath the passenger side of the instrument panel. 3. On RHD models, remove the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 4. Disconnect the wire harness connector (1) from the blend door actuator (2) located on the left side of the HVAC air distribution housing (3). 5. Remove the two screws (4) that secure the blend door actuator to the air distribution housing and remove the actuator. DUAL ZONE RIGHT SIDE 1. Disconnect and isolate the negative battery cable. 2. On LHD models, if equipped, remove the silencer from underneath the passenger side of the instrument panel. 3. On LHD models, remove the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6988 4. Remove the front floor distribution duct from the right side of the air distribution housing See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. 5. Remove the screws (2) that secure the blend door actuator (1) to the right side of the air distribution housing (4) and remove the actuator from the housing. 6. Disconnect the wire harness connector (3) from the blend door actuator and remove the actuator from the vehicle. Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove rear heater-A/C housing (4) and place it on a workbench . 3. Disconnect the wire harness connector (3) from the rear blend door actuator (2) located on the outboard side of the rear heater-A/C housing. 4. Remove the two screws (1) that secure the rear blend door actuator to the rear heater-A/C housing and remove the actuator. Front INSTALLATION NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. NOTE: LHD model shown in illustrations. SINGLE ZONE/DUAL ZONE LEFT SIDE 1. Position the blend door actuator (2) onto the left side of the HVAC air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. 2. Install the two screws (4) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the wire harness connector (1) to the blend door actuator. 4. On RHD models, install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6989 Panel Glove Box - Installation. 5. On RHD models, if equipped, install the silencer underneath the instrument panel. 6. Reconnect the negative battery cable. 7. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. DUAL ZONE RIGHT SIDE 1. Position the blend door actuator (1) to the right side of the HVAC air distribution housing (4) and connect the wire harness connector (3) to the actuator. 2. Install the blend door actuator onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator with the blend door linkage. 3. Install the two screws (2) that secure the blend door actuator to the air distribution housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 4. Install the right front floor distribution duct onto the air distribution housing See: Air Duct/Service and Repair/Floor Distribution Duct Installation. 5. On LHD models, install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. 6. On LHD models, if equipped, install the silencer underneath the instrument panel. 7. Reconnect the negative battery cable. 8. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION 1. Position the rear blend door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear blend-air door pivot shaft (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6990 2. Install the two screws (1) that secure the rear blend door actuator (2) to the rear heater-A/C housing (4). Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (3) to the rear blend door actuator. 4. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 3. Remove the screws (1) that secure the mode door actuator (4) to the bracket (5) located on the right side of the HVAC air distribution housing (2). 4. Disconnect the wire harness connector (3) from the mode door actuator and remove the actuator. Rear REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6991 1. Disconnect and isolate the negative battery cable. 2. Remove rear heater-A/C housing (3) and place it on a workbench . 3. Disconnect the wire harness connector (4) from the rear mode door actuator (2) located on the outboard side of the rear heater-A/C housing. 4. Remove the two screws (1) that secure the rear mode door actuator to rear heater-A/C housing and remove the actuator. Front INSTALLATION 1. Position the mode door actuator (4) onto the bracket (5) located on the right side of the HVAC air distribution housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode air door linkage. 2. Install the screws (1) that secure the mode door actuator to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the wire harness connector (3) to the mode door actuator. 4. Install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6992 1. Position the rear mode door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear mode-air door pivot shaft (2). 2. Install the two screws (1) that secure the rear mode door actuator (2) to the rear heater-A/C housing (3). Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (4) to the rear mode door actuator. 4. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Recirculation Door Actuator - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with instrument panel removed for clarity. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6993 NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 3. Reach through the glove box opening in the instrument panel and remove the screws (1) that secure the recirculation door actuator (2) to the right side of the HVAC air inlet housing (3). 4. Disconnect the wire harness connector (4) from the recirculation door actuator and remove the actuator. Recirculation Door Actuator - Installation INSTALLATION NOTE: Illustrations shown with instrument panel removed for clarity. NOTE: LHD model shown. 1. Position the recirculation door actuator (1) to the right side of the HVAC air inlet housing (2). 2. Install the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 6994 3. Install the screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 4. Connect the instrument panel wire harness connector (4) to the recirculation door actuator. 5. Install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 6. Reconnect the negative battery cable. 7. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal Air Duct: Service and Repair Defroster Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet - Removal. 3. Remove the cover from the instrument panel. 4. Remove the driver side outboard instrument panel and demister duct assembly See: Instrument Panel Duct - Removal. 5. Disengage the two retaining clips (2) that secure the wire harness lead (3) to the top of the defroster duct (1). 6. Disconnect the defroster duct from the passenger side demister duct (4) and remove the defroster duct from the instrument panel support (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 6999 Air Duct: Service and Repair Defroster Duct - Installation INSTALLATION NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown. 1. Position the defroster duct (1) to the top of the instrument panel support (5) and connect it to the passenger side demister duct (4). 2. Engage the two retaining clips (2) that secure the wire harness lead (3) to the top of the defroster duct. 3. Install the driver side instrument panel and demister duct assemblySee: Instrument Panel Duct - Installation. 4. Install the cover onto the instrument panel support. 5. Install the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet - Installation. 6. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7000 Air Duct: Service and Repair Floor Distribution Duct - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown in illustrations. RIGHT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. 1. On LHD models, remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. 1. On RHD models, remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 2. On LHD models, disconnect the shift interlock cable (3) from the left floor duct (1) and position the cable out of the way. 3. Remove the screw (4) that secures the left floor duct to the left side of the HVAC housing (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7001 4. Disconnect the left floor duct from the HVAC housing and remove the duct. REAR FLOOR DISTRIBUTION DUCTS 1. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 2. Remove the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required from the HVAC housing (3) and remove the duct(s). REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. 1. Remove the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 2. Remove the front seat from the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Removal. 3. Pull the carpet back to gain access to the rear seat floor duct (2) See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Removal. 4. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor support (4). 5. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat duct(s). Rear REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7002 1. Remove right quarter trim panel, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 2. Remove the push-pin retainer (2) that secures the rear floor distribution duct (1) to the right inner quarter panel (3). 3. Disengage the rear floor distribution duct from the stud (5) located on the right inner quarter panel. 4. Disengage the rear floor distribution duct from the rear heater-A/C housing (4) and remove the duct. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7003 Air Duct: Service and Repair Floor Distribution Duct - Installation Front INSTALLATION NOTE: LHD model shown in illustrations. RIGHT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. 1. Connect the right floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. On LHD models, install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. 1. Connect the left floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the screw (4) that secures the left floor duct to the HVAC housing. Tighten the screw to 2 Nm (17 in. lbs.). 3. On LHD models, connect the shift interlock cable (3) to the left floor duct. 4. On RHD models, install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. REAR FLOOR DISTRIBUTION DUCTS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7004 1. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing. 2. Install the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. 1. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other. 2. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reinstall the carpet See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Installation. 4. Install the front seat to the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Installation. 5. Install the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7005 1. Install the rear floor distribution duct (1) onto rear heater-A/C housing (4). Make sure the duct is fully engaged to the housing. 2. Engage the rear floor distribution duct to the stud (5) located on the right inner quarter panel (3). 3. Install the push-pin retainer (2) that secures the rear floor distribution duct to the right inner quarter panel. 4. Install the right quarter panel trim, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7006 Air Duct: Service and Repair Defroster Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet - Removal. 3. Remove the cover from the instrument panel. 4. Remove the driver side outboard instrument panel and demister duct assembly See: Instrument Panel Duct - Removal. 5. Disengage the two retaining clips (2) that secure the wire harness lead (3) to the top of the defroster duct (1). 6. Disconnect the defroster duct from the passenger side demister duct (4) and remove the defroster duct from the instrument panel support (5). Defroster Duct - Installation INSTALLATION NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7007 1. Position the defroster duct (1) to the top of the instrument panel support (5) and connect it to the passenger side demister duct (4). 2. Engage the two retaining clips (2) that secure the wire harness lead (3) to the top of the defroster duct. 3. Install the driver side instrument panel and demister duct assemblySee: Instrument Panel Duct - Installation. 4. Install the cover onto the instrument panel support. 5. Install the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet - Installation. 6. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown in illustrations. RIGHT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. 1. On LHD models, remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct. LEFT FRONT FLOOR DUCT Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7008 NOTE: Illustration shown with instrument panel removed for clarity. 1. On RHD models, remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 2. On LHD models, disconnect the shift interlock cable (3) from the left floor duct (1) and position the cable out of the way. 3. Remove the screw (4) that secures the left floor duct to the left side of the HVAC housing (2). 4. Disconnect the left floor duct from the HVAC housing and remove the duct. REAR FLOOR DISTRIBUTION DUCTS 1. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 2. Remove the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required from the HVAC housing (3) and remove the duct(s). REAR SEAT FLOOR DUCTS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7009 NOTE: Right side rear floor duct shown. Left side duct similar. 1. Remove the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 2. Remove the front seat from the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Removal. 3. Pull the carpet back to gain access to the rear seat floor duct (2) See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Removal. 4. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor support (4). 5. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat duct(s). Rear REMOVAL 1. Remove right quarter trim panel, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 2. Remove the push-pin retainer (2) that secures the rear floor distribution duct (1) to the right inner quarter panel (3). 3. Disengage the rear floor distribution duct from the stud (5) located on the right inner quarter panel. 4. Disengage the rear floor distribution duct from the rear heater-A/C housing (4) and remove the duct. Front INSTALLATION NOTE: LHD model shown in illustrations. RIGHT FRONT FLOOR DUCT Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7010 NOTE: Illustration shown with instrument panel removed for clarity. 1. Connect the right floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. On LHD models, install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. 1. Connect the left floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the screw (4) that secures the left floor duct to the HVAC housing. Tighten the screw to 2 Nm (17 in. lbs.). 3. On LHD models, connect the shift interlock cable (3) to the left floor duct. 4. On RHD models, install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. REAR FLOOR DISTRIBUTION DUCTS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7011 1. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing. 2. Install the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. 1. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other. 2. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reinstall the carpet See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Installation. 4. Install the front seat to the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Installation. 5. Install the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. Rear INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7012 1. Install the rear floor distribution duct (1) onto rear heater-A/C housing (4). Make sure the duct is fully engaged to the housing. 2. Engage the rear floor distribution duct to the stud (5) located on the right inner quarter panel (3). 3. Install the push-pin retainer (2) that secures the rear floor distribution duct to the right inner quarter panel. 4. Install the right quarter panel trim, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. Instrument Panel Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The left and right instrument panel ducts are serviced with the left and right demister ducts as an assembly. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown in illustrations. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet - Removal. 3. Remove the cover from the instrument panel. 4. Remove the two push-pin retainers (4) that secure the driver side instrument panel and demister duct assembly (1) to the top of the instrument panel support (5). 5. Disconnect the driver side instrument panel and demister duct assembly from the instrument panel center duct (2) and the defroster duct (3) and remove the driver side instrument panel and demister duct assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7013 6. Remove the two push-pin retainers (4) that secure the passenger side instrument panel and demister duct assembly (1) to the top of the instrument panel support (5). 7. Disconnect the passenger side instrument panel and demister duct assembly from the instrument panel center duct (2) and the defroster duct (3) and remove the passenger side instrument panel and demister duct assembly. 8. Remove the two screws (2 and 4) that secure the instrument panel center duct (1) to the instrument panel support (3) and remove the center duct. Instrument Panel Duct - Installation INSTALLATION NOTE: The left and right instrument panel ducts are serviced with the left and right demister ducts as an assembly. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown in illustrations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7014 1. Position the instrument panel center duct (3) to the instrument panel support (4) and install the two retaining screws (2 and 4). Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Position the passenger side instrument panel and demister duct assembly (1) to the instrument panel support (5) and connect the instrument panel and demister duct assembly to the center duct (2) and to the defroster duct (3). Make sure the ducts are fully engaged. 3. Install the two push-pin retainers (4) that secure the passenger side instrument panel and demister duct assembly to the instrument panel support. 4. Position the driver side instrument panel and demister duct assembly (1) to the instrument panel support (5) and connect the instrument panel and demister duct assembly to the center duct (2) and to the defroster duct (3). Make sure the ducts are fully engaged. 5. Install the two push-pin retainers (4) that secure the driver side instrument panel and demister duct assembly to the instrument panel support. 6. Install the cover onto the instrument panel. 7. Install the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet Installation. 8. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7015 Instrument Panel Demister Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The left and right demister ducts are serviced with the left and right instrument panel ducts as an assembly. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown in illustrations. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet - Removal. 3. Remove the cover from the instrument panel. 4. Remove the two push-pin retainers (4) that secure the driver side instrument panel and demister duct assembly (1) to the top of the instrument panel support (5). 5. Disconnect the driver side instrument panel and demister duct assembly from the instrument panel center duct (2) and the defroster duct (3) and remove the driver side instrument panel and demister duct assembly. 6. Remove the two push-pin retainers (4) that secure the passenger side instrument panel and demister duct assembly (1) to the top of the instrument panel support (5). 7. Disconnect the passenger side instrument panel and demister duct assembly from the instrument panel center duct (2) and the defroster duct (3) and remove the passenger side instrument panel and demister duct assembly. Instrument Panel Demister Duct - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7016 INSTALLATION NOTE: The left and right demister ducts are serviced with the left and right instrument panel ducts as an assembly. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. NOTE: LHD model shown in illustrations. 1. Position the passenger side instrument panel and demister duct assembly (1) to the instrument panel support (5) and connect the instrument panel and demister duct assembly to the center duct (2) and to the defroster duct (3). Make sure the ducts are fully engaged. 2. Install the two push-pin retainers (4) that secure the passenger side instrument panel and demister duct assembly to the instrument panel support. 3. Position the driver side instrument panel and demister duct assembly (1) to the instrument panel support (5) and connect the instrument panel and demister duct assembly to the center duct (2) and to the defroster duct (3). Make sure the ducts are fully engaged. 4. Install the two push-pin retainers (4) that secure the driver side instrument panel and demister duct assembly to the instrument panel support. 5. Install the cover onto the instrument panel. 6. Install the outboard instrument panel air outlets See: Air Register/Service and Repair/Air Outlet Installation. 7. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Ceiling Distribution Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7017 1. Disconnect and isolate the negative battery cable. 2. Remove the right D-pillar trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 3. Remove right quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 4. Remove the two bolts (2) that secure the upper seat belt bracket (1) to the right D-pillar (3) and remove the bracket. 5. Remove the two bolts (4) that secure the right seat belt retractor (5) to the right D-pillar and remove the retractor. 6. Remove the two retainers (4 and 5) that secure the rear ceiling distribution duct (3) to the right D-pillar (2). 7. Lift the rear ceiling distribution duct upward and disengage it from the rear heater-A/C housing (1). CAUTION: Use care when removing the rear ceiling distribution duct from the heater-A/C housing to prevent damage to the molded plastic support brace located on the top of the housing outlet. Failure to follow this caution could result in part of, or all of the support brace falling into the rear housing, which may interfere with rear mode door operation. 8. Pull the bottom end of the rear ceiling distribution duct away from the rear heater-A/C housing and remove the duct. Ceiling Distribution Duct - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7018 1. Position the rear ceiling distribution duct (3) to the right D-pillar (2). CAUTION: Use care when installing the rear ceiling distribution duct onto the heater-A/C housing to prevent damage to the molded plastic support brace located on the top of the housing outlet. Failure to follow this caution could result in part of, or all of the support brace falling into the rear housing, which may interfere with rear mode door operation. 2. Install the rear ceiling distribution duct onto the top of the rear heater-A/C housing (1). Make sure the duct is fully engaged to the housing. 3. Install the two retainers (4 and 5) that secure the rear ceiling distribution duct to the right D-pillar. 4. Position the upper seat belt bracket (2) onto the D-pillar (3) and install the two retaining bolts (1). Tighten the bolts to 52 Nm (38.5 ft. lbs.). 5. Install the right seat belt retractor (5) and retaining bolts (4) onto the D-pillar. Tighten the bolts to 52 Nm (38.5 ft. lbs.). 6. Install the right quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Install the right D-pillar trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation 8. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Description and Operation Air Register: Description and Operation DESCRIPTION There are two defroster air outlets (1) in the defroster grille (2) located at the top of the instrument panel. The airflow from the defroster outlets are directed by fixed vanes in the grille and cannot be adjusted. The defroster air outlets are not serviceable from the defroster grille. There are two side window demister air outlets (3 and 5). One located on each end of the instrument panel. The airflow from the side window demister air outlets is directed by fixed vanes and cannot be adjusted. The side window demister air outlets can be serviced separately from the instrument panel. There are four instrument panel air outlets (4). One air outlet is located near each outboard end of the instrument panel facing the rear of the vehicle and two air outlets are located at the top of the instrument panel center bezel. Each of the instrument panel air outlets contain movable vanes that can direct or shut off the flow of the conditioned air leaving the outlets. The instrument panel air outlets can be serviced separately from the instrument panel. Some models with A/C are equipped with a cooled beverage storage bin located in the instrument panel. Vehicles so equipped have an outlet, which, when opened with the A/C on, allows cooled air to flow into the bin. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal Air Register: Service and Repair Defroster Grille - Removal REMOVAL 1. Remove the left and right A-pillar trim panels. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Removal. 2. Using trim stick C4755 or equivalent, pry up on defroster grille disengaging clips. 3. Remove defroster grille from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7024 Air Register: Service and Repair Defroster Grille - Installation INSTALLATION 1. Position the defroster grille in place and align the spring retainers with the instrument panel. 2. Hand tap defroster grille in place ensuring proper seat. 3. Install the left and right A-pillar trim panels. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7025 Air Register: Service and Repair Air Outlet - Removal Demister Outlets DEMISTER OUTLETS WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Right side air outlet shown. Left side outlet similar. 1. Using Trim Stick C-4755 or equivalent (2), carefully disengage the three retaining tabs that secure each demister air outlet (1) to the instrument panel cover (3) and remove the outlet. Air Outlets AIR OUTLETS WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. OUTBOARD OUTLETS NOTE: Right side air outlet shown. Left side outlet similar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7026 1. Using trim stick C-4755 or equivalent (2), carefully disengage the four retaining tabs (two tabs on each side) that secure each air outlet (1) to the instrument panel cover (3) and remove the outlet. CENTER OUTLETS NOTE: Take the proper precautions to protect the front face of the center bezel from cosmetic damage while performing this procedure. 1. Remove the center bezel (3) from the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 2. Remove the four screws (2 and 4) that secure the center instrument panel air outlets (1) to the center bezel and remove the outlets. Rear REMOVAL 1. Rotate the air outlet (1) being serviced clockwise until the retaining tabs on the back of the outlet disengage from the headliner (2). 2. Remove the air outlet from the headliner. Beverage Cooler BEVERAGE COOLER WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown in illustrations. OUTLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7027 1. Using Trim Stick C-4755 or equivalent (1), disengage the three retaining tabs that secure the beverage cooler outlet (2) to side of the glove box bin (3). NOTE: If the beverage cooler cold air supply hose becomes disconnected from the air beverage cooler outlet and falls back into the instrument panel during outlet removal, the beverage cooler bin may need to be removed from the instrument panel for outlet installation See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Beverage Cooler Bin - Removal. 2. Carefully pull the beverage cooler outlet (1) away from side of the beverage cooler bin (3) and disconnect the cold air supply hose (2) from the outlet. Make sure the end of the cold air supply hose remains in the bin and does not fall back into the instrument panel. COLD AIR SUPPLY HOSE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7028 NOTE: Illustration shown with instrument panel removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the outer passenger side instrument panel air outlet See: . 4. Remove the beverage cooler outlet (refer to OUTLET - REMOVAL). 5. Remove the beverage cooler bin See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Beverage Cooler Bin - Removal. 6. If equipped, remove the silencer trim panel out from underneath the passenger side of the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel Removal. 7. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 8. Reach up underneath the instrument panel and disconnect the cold air supply hose (1) from the passenger side of the air distribution housing (3). 9. Working through the beverage cooler bin opening in the instrument panel, disengage the cold air supply hose from the bracket (4) located on the air inlet housing (2) and remove the hose. Note the routing of the hose and the instrument panel wiring for aid in reinstallation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7029 Air Register: Service and Repair Air Outlet - Installation Air Outlets AIR OUTLETS OUTBOARD OUTLETS NOTE: Right side air outlet shown. Left side outlet similar. 1. Position the air outlet (1) to the opening in the instrument panel cover (2) and align the outlet to the instrument panel duct. NOTE: Make sure that the air outlet(s) are properly aligned to the instrument panel duct(s). 2. Engage the four retaining tabs that secure each instrument panel outlet to the instrument panel cover. Make sure the retaining tabs are fully engaged. CENTER OUTLETS NOTE: Take the proper precautions to protect the front face of the center bezel from cosmetic damage while performing this procedure. 1. Position the air outlets (1) to the back of the center bezel (3) and install the four retaining screws (2 and 4). Tighten the screws to 1.2 Nm (10 in. lbs.). NOTE: Make sure that the air outlets are properly aligned to the instrument panel center duct. 2. Install the center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7030 Demister Outlets DEMISTER OUTLETS NOTE: Right side demister outlet shown. Left side outlet similar. 1. Position the demister air outlet (1) to the opening in the instrument panel cover (2) and engage the three retaining tabs. Make sure the retaining tabs are fully engaged. Rear INSTALLATION 1. Position the air outlet (1) being serviced to the opening in the headliner (2). 2. Rotate the air outlet counterclockwise until the retaining tabs on the back of the outlet are fully engaged to the headliner. Beverage Cooler BEVERAGE COOLER NOTE: LHD model shown in illustrations. OUTLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7031 NOTE: If the beverage cooler cold air supply hose falls back into the instrument panel during outlet installation, the beverage cooler bin may need to be removed from the instrument panel and the hose rerouted through the opening in the bin See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Removal. 1. Position the beverage cooler outlet (1) to the beverage cooler bin (3) and connect the cold air supply hose (2) to the outlet. 2. Feed the cold air supply hose through the opening in the side of the beverage cooler bin (1) and align and install the beverage cooler outlet (2) onto the bin. Make sure the three retaining tabs on the outlet are fully engaged to the bin. COLD AIR SUPPLY HOSE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7032 NOTE: Illustration shown with instrument panel removed for clarity. 1. Working through the beverage cooler bin opening in the instrument panel, feed the cold air supply hose (1) into the instrument panel. Note the routing of the hose and the instrument panel wiring. 2. Reach up underneath the instrument panel and connect the cold air supply hose to the passenger side of the air distribution housing (3). 3. Working through the beverage cooler bin opening in the instrument panel, engage the cold air supply hose to the bracket (4) located on the air inlet housing (2). 4. Position the beverage cooler bin to the instrument panel and route the cold air supply hose through the beverage cooler outlet opening. 5. Install the beverage cooler bin See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Beverage Cooler Bin - Installation. 6. Install the beverage cooler outlet (refer to OUTLET - INSTALLATION). 7. Install the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 8. Install the outer passenger side instrument panel air outlet See: . 9. Install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 10. If equipped, install the silencer trim panel underneath the passenger side of the instrument panel \See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 11. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7036 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (FRONT END MODULE) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Description DESCRIPTION The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ATC system uses the sensor data to maintain optimum cabin temperature levels. The ambient air temperature sensor is mounted inside the front fascia. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description > Page 7039 Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Operation OPERATION The ambient air temperature sensor is a variable resistor that operates on a 5-volt reference signal sent by the Totally Integrated Power Module (TIPM). The ambient air temperature sensor is connected to the TIPM through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes its internal resistance in response to changes in the outside air temperature, which either increases or decreases the reference signal voltage read by the TIPM. The TIPM converts and broadcasts the sensor data over the Controller Area Network (CAN) IHS bus, where it is read by the ATC A/C-heater control, Powertrain Control Module (PCM) and other vehicle control modules. The ambient air temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Cabin Heater > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Cabin Heater > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 > Page 7045 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Cabin Heater > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 > Page 7046 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Front Blower Motor Blower Motor: Locations Front Blower Motor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Front Blower Motor > Page 7051 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Front Blower Motor > Page 7052 Blower Motor: Locations Rear Blower Motor (3 Zone HVAC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Front Blower Motor > Page 7053 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Blower Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Blower Motor: Connector Views Front Blower Motor (Instrument Panel) 2 Way Connector - (INSTRUMENT PANEL) 2 WAY MOTOR-BLOWER-FRONT - (INSTRUMENT PANEL) 2 WAY Rear Blower Motor (3 Zone HVAC) (Body) 2 Way Connector (3 ZONE HVAC) - (BODY) 2 WAY MOTOR-BLOWER-REAR (3 ZONE HVAC) - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front Blower Motor: Description and Operation Description - Front DESCRIPTION The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel (2) within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (3) and three mounting tabs (4). The squirrel cage-type blower wheel is secured to the blower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front > Page 7074 Blower Motor: Description and Operation Description - Rear DESCRIPTION The rear blower motor (1) is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire connector (4) and a squirrel cage-type blower wheel (3) that is secured to the blower motor shaft. Three integral mounting tabs (2) and a lock tab (5) secure the blower motor to the inboard side of the rear heater-A/C housing. The rear blower motor can be accessed for service without removing the rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front > Page 7075 Blower Motor: Description and Operation Operation - Front OPERATION The blower motor controls the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. On the Manual Temperature Control (MTC) heating-A/C system, blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. With the Automatic Temperature Control (ATC) heating-A/C system, blower motor speed is controlled by an electronic blower motor power module, that uses a Pulse Width Modulated (PWM) input from the A/C-heater control and a feedback signal from the blower motor to regulate the blower motor ground path. On both systems, the blower motor receives battery current through the Totally Integrated Power Module (TIPM) whenever the ignition switch is in the Run position, and the blower motor control is in any position except Off. The blower motor can be accessed for service from underneath the instrument panel. NOTE: The blower motor is supplied with a 12 volt feed from the TIPM whenever the ignition switch is in the Run position. Due to an open circuit condition within the blower motor control switch, the TIPM is unable to detect an open circuit for the blower motor. The blower motor control system is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front > Page 7076 Blower Motor: Description and Operation Operation - Rear OPERATION The rear blower motor is used to control the velocity of air moving through the rear heater-A/C housing by spinning the blower wheel within the heater-A/C housing at the selected speed. The rear blower motor will only operate when the ignition switch is in ON and the rear blower motor switch located in the front accessory switch panel is ON. The rear blower motor receives a battery feed through the totally integrated power module (TIPM), whenever the ignition switch is in ON See: Testing and Inspection. The rear blower motor and blower wheel are factory balanced and cannot be adjusted or repaired and must be replaced as an assembly if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 7077 Blower Motor: Testing and Inspection BLOWER MOTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The blower motor is supplied with a 12V feed from the TIPM whenever the ignition switch is in RUN. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. See Wiring Information for circuit descriptions and diagrams. OPERATION Possible causes of an inoperative blower motor include: - Open fuse - Inoperative blower motor resistor - Inoperative blower motor switch - Inoperative blower motor - Inoperative blower motor circuit wiring or wire harness connectors NOISE To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: - Foreign material on fresh air inlet screen - Foreign material in blower wheel - Foreign material in HVAC housing - Improper blower motor mounting - Deformed or damaged blower wheel - Worn blower motor bearings or brushes VIBRATION Possible causes of a blower motor vibration include: - Improper blower motor mounting - Foreign material in blower wheel - Deformed or damaged blower wheel - Worn blower motor bearings Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front Blower Motor: Service and Repair Removal - Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector (1) from the blower motor (2). 4. Remove the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to the bottom of the HVAC housing (5) and remove the blower motor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front > Page 7080 Blower Motor: Service and Repair Removal - Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the wire harness connector (3) from the rear blower motor (1). 4. Disengage the locking tab (4) and remove the rear blower motor from the rear heater-A/C housing (2) by turning the blower motor counterclockwise. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front > Page 7081 Blower Motor: Service and Repair Installation - Front INSTALLATION NOTE: LHD model shown. 1. Position the blower motor (2) into the bottom of the HVAC housing (5). 2. Install the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the instrument panel wire harness connector (1) to the blower motor and engage the connector lock. 4. If equipped, install the silencer below the passenger side of the instrument panel. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front > Page 7082 Blower Motor: Service and Repair Installation - Rear INSTALLATION 1. Position the rear blower motor (1) into the rear heater-A/C housing (2) and rotate the blower motor clockwise until the blower motor is fully engaged to the housing and the retaining tab (4) is in the locked position. 2. Connect the wire harness connector (3) to the rear blower motor. 3. Install the right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7086 Blower Motor Relay: Diagrams Connector (3 ZONE HVAC) - (IN TIPM) 5 WAY RELAY-REAR BLOWER MOTOR (3 ZONE HVAC) - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor (MTC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor (MTC) > Page 7091 Blower Motor Resistor: Locations Rear Blower Motor Resistor (3 Zone MTC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor (MTC) > Page 7092 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor (MTC) (Instrument Panel) 4 Way Blower Motor Resistor: Diagrams Front Blower Motor Resistor (MTC) (Instrument Panel) 4 Way Connector (MTC) - (INSTRUMENT PANEL) 4 WAY RESISTOR-BLOWER MOTOR-FRONT (MTC) - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor (MTC) (Instrument Panel) 4 Way > Page 7095 Blower Motor Resistor: Diagrams Rear Blower Motor Resistor (3 Zone MTC) (Body) 4 Way Connector (3 ZONE MTC) - (BODY) 4 WAY RESISTOR-BLOWER MOTOR-REAR (3 ZONE MTC) - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front Blower Motor Resistor: Description and Operation Description - Front DESCRIPTION A blower motor resistor is used on vehicles equipped with the manual temperature control (MTC) heating-A/C system. Vehicles equipped with the automatic temperature control (ATC) heating-A/C system use a blower motor power module, instead of the blower motor resistor See: Control Module HVAC/Description and Operation/Front Blower Motor Power Module - Description. The blower motor resistor is mounted to the bottom of the HVAC housing, on the passenger side of the vehicle. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are resistors (3) located between a two-piece stamped steel base (4). The blower motor resistor is accessed for service from under the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front > Page 7098 Blower Motor Resistor: Description and Operation Description - Rear DESCRIPTION A blower motor resistor is used on this model when equipped with the manual temperature control (MTC) rear heating-A/C system. Models equipped with the automatic temperature control (ATC) rear heating-A/C system use a blower motor power module, instead of the blower motor resistor See: Control Module HVAC/Description and Operation/Rear Blower Motor Power Module Description. The rear blower motor resistor is mounted to the inboard side of the rear heating-A/C housing, located on the right side of the vehicle. The rear blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are resistors (3) located between a two-piece stamped steel heat sink (4). The rear blower motor resistor can be accessed for service without removing the rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front > Page 7099 Blower Motor Resistor: Description and Operation Operation - Front OPERATION The blower motor resistor is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The blower motor resistor has three resistors, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor control for the heating-A/C system directs the ground path for the blower motor through the correct resistor to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the blower motor is applied through all of the resistors. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistors, increasing the blower motor speed. When the blower motor control is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground. The blower motor resistor cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front > Page 7100 Blower Motor Resistor: Description and Operation Operation - Rear OPERATION The blower motor resistor for the rear heating-A/C system is connected to the vehicle electrical system through a dedicated wire lead and connector of the rear heater-A/C wire harness. The rear blower motor resistor has an electrical circuit board with three resistors, each of which will reduce the current flow through the rear blower motor to change the blower motor speed. The blower motor switch for the MTC rear heater-A/C system directs the ground path for the rear blower motor through the correct resistor to obtain the selected speed. With the rear blower motor control in the lowest speed position, the ground path for the rear blower motor is applied through all of the resistors. Each higher speed selected with the rear blower motor control applies the blower motor ground path through fewer of the resistors, increasing the rear blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistors are bypassed and the blower motor receives a direct path to ground through the rear blower motor switch. The rear blower motor resistor cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor Blower Motor Resistor: Testing and Inspection Front Blower Motor Resistor BLOWER MOTOR RESISTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: See Wiring Information for circuit descriptions and diagrams. Wiring Information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor . 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor speed control and the blower motor resistor or blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor > Page 7103 Blower Motor Resistor: Testing and Inspection Rear Blower Motor Resistor REAR BLOWER MOTOR RESISTOR NOTE: See Wiring Information for circuit descriptions and diagrams. Wiring Information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor . 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or the blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front Blower Motor Resistor: Service and Repair Removal - Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before performing diagnosis or service. Failure to take this precaution may result in possible injury. CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the blower motor resistor (2) located at the bottom of the HVAC housing (3) on the passenger side of the vehicle. 3. Remove the two screws (4) that secure the blower motor resistor to the HVAC housing and remove the resistor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front > Page 7106 Blower Motor Resistor: Service and Repair Removal - Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the wire harness connector (4) from the rear blower motor resistor (3). 4. Remove the two screws (1) that secure the rear blower motor resistor to the rear heater-A/C housing (2) and remove the resistor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front > Page 7107 Blower Motor Resistor: Service and Repair Installation - Front INSTALLATION NOTE: LHD model shown. 1. Position the blower motor resistor (2) onto the bottom of the HVAC housing (3). 2. Install the two screws (4) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor resistor. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front > Page 7108 Blower Motor Resistor: Service and Repair Installation - Rear INSTALLATION 1. Position the rear blower motor resistor (3) onto the rear heater-A/C housing (2). 2. Install the two screws (1) that secure the rear blower motor resistor to the rear heater-A/C housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (4) to the rear blower motor resistor. 4. Install the right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Description and Operation Cabin Air Filter: Description and Operation DESCRIPTION Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin. The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures Cabin Air Filter: Procedures WARNING: Do not remove the A/C air filter while the blower is operating or personal injury may result. The A/C air filter is located in the fresh air inlet behind the glove box. Perform the following steps to replace the filter: 1. Open the glove box and remove all contents. 2. Push the retaining tab on each side of the glove box inward while gently pulling the glove box door outward until both tabs clear the door opening in the instrument panel. 3. Pivot the glove box downward. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 7114 4. Disengage the two retaining tabs that secure the filter cover to the HVAC housing and remove the cover. 5. Remove the A/C air filter by pulling it straight out of the housing. 6. Install the A/C air filter with the arrow on the filter pointing toward the floor. When installing the filter cover, make sure the retaining tabs fully engage the cover. CAUTION: The A/C air filter is labeled with an arrow to indicate airflow direction through the filter. Failure to install the filter properly will result in the need to replace it more often. 7. Reinstall the glove box door. Make sure that the hinges are seated fully as you raise the door. Otherwise, the door latch will not align properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 7115 Cabin Air Filter: Removal and Replacement Particulate Air Filter - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Always make sure the A/C-heater system is turned off and that the ignition switch is in the OFF position prior to servicing the particulate air filter. Never place fingers or other objects into the filter opening of the HVAC housing. Failure to follow this warning may result in serious injury. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. Particulate Air Filter - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 7116 INSTALLATION NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE: LHD model shown in illustrations. 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications CLUTCH GAP Air Gap................................................................................................................................................. ..............................0.35 - 0.60 mm (0.014 - 0.024 in.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7121 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7122 Compressor Clutch: Diagrams Connector (PAC) - (ENGINE) 2 WAY CLUTCH-A/C COMPRESSOR (PAC) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Compressor Clutch - Description Compressor Clutch: Description and Operation A/C Compressor Clutch - Description CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR NOTE: Typical A/C clutch assembly shown. The clutch assembly for the Denso 10SR15 and 10SR17 fixed displacement A/C compressors consists of a stationary electromagnetic A/C clutch field coil (4), pulley bearing and pulley assembly (3), clutch plate (2) and shims (7). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch field coil and the pulley bearing and pulley assembly are both retained on the nose of the A/C compressor with snap rings (5 and 6). The clutch plate is splined to the compressor shaft and secured with a bolt (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Compressor Clutch - Description > Page 7125 Compressor Clutch: Description and Operation A/C Compressor Clutch - Operation CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR The clutch components for the Denso 10SR15 and 10SR17 fixed displacement A/C compressor provide the means to engage and disengage the compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly. A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-IHS bus to the totally integrated power module (TIPM), which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the totally integrated power module (TIPM) to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil. The A/C clutch control system is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C compressor clutch components cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Fixed Displacement A/C Compressor Clutch Inspection Compressor Clutch: Testing and Inspection Fixed Displacement A/C Compressor Clutch Inspection CLUTCH INSPECTION - FIXED DISPLACEMENT A/C COMPRESSOR Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and clutch plate if required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Fixed Displacement A/C Compressor Clutch Inspection > Page 7128 Compressor Clutch: Testing and Inspection Fixed Displacement A/C Compressor Clutch CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR The compressor clutch coil electrical circuit for the Denso 10SR15 and 10SR17 fixed displacement A/C compressors is controlled by the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) through the totally integrated power module (TIPM) (refer to the appropriate wiring information for complete HVAC wiring diagrams). Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS 1. Using a scan tool, check for diagnostic trouble codes (DTCs) in the A/C-heater control, TIPM and PCM/ECM. If no diagnostic trouble codes (DTCs) are found, go to 2. If any DTCs are found, repair as required. 2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level See: Testing and Inspection/Component Tests and General Diagnostics. If the refrigerant charge level is OK, go to COIL RESISTANCE TEST and/or COIL CURRENT DRAW TEST. If the refrigerant charge level is not OK, adjust the refrigerant charge as required. COIL RESISTANCE TEST 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the A/C clutch field coil connector. 3. Use an ohm meter and Back Probe Tool 6801 and measure the resistance of the clutch field coil at the field coil connector terminals. 4. Refer to the A/C Clutch Field Coil Specifications chart for the acceptable A/C clutch coil resistance. Specifications apply for a work area temperature of 21° C (70° F). a. If the A/C clutch coil reading is below specifications, the coil is shorted and must be replaced. b. If the A/C clutch coil reading is above specifications, the coil is open and must be replaced. COIL CURRENT DRAW TEST 1. Verify the battery state of charge See: Starting and Charging/Battery/Testing and Inspection/Component Tests and General Diagnostics/Battery. 2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal using Back Probe Tool 6801. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. 3. With the heater-A/C control in the A/C mode and the blower at low speed, start the engine and allow it to run at a normal idle speed. 4. The compressor clutch should engage immediately, and the clutch coil supply voltage should be within two volts of the battery voltage. If the coil supply voltage is OK, go to 5. If the coil supply voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary. 5. Refer to the A/C Clutch Field Coil Specifications chart for the acceptable A/C clutch field coil current draw. Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. a. If the compressor clutch coil current reading is zero, the coil is open and must be replaced. b. If the compressor clutch coil current reading is above specifications, the coil is shorted and must be replaced. A/C CLUTCH FIELD COIL SPECIFICATIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal Compressor Clutch: Service and Repair A/C Compressor Clutch - Removal CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged and with the A/C compressor installed on the engine. NOTE: Typical A/C compressor and clutch assembly shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle. 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 4. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). NOTE: Some models (depending on engine application) may require the A/C compressor to be removed from its installed location and repositioned to gain access to the compressor shaft bolt and/or pulley and field coil snap rings. However, the refrigerant system can still remain fully charged. 6. If necessary, remove the bolts that secure the A/C compressor to the engine and reposition the compressor to gain access to the shaft bolt and/or pulley and field coil snap rings See: Service and Repair/A/C Compressor - Removal. 7. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2). 8. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7131 CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process. 9. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3). 10. Using A/C Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7132 11. Using A/C Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7133 Compressor Clutch: Service and Repair A/C Compressor Clutch - Installation CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR NOTE: Typical A/C compressor and clutch assembly shown in illustrations. 1. Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor. 2. Using A/C Snap Ring Pliers 9764 or equivalent (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: Be certain to position the A/C clutch coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the A/C clutch will result. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7134 3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 4. Using A/C Snap Ring Pliers 9764 or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7135 6. Install the clutch plate (4) onto the front of the A/C compressor (5). 7. Install the compressor shaft bolt (3). Tighten the bolt to 19 Nm (168 in. lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap. 8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained. CAUTION: Be certain that the compressor clutch coil wire lead is routed so that it is not pinched between the A/C compressor and the coil connector bracket. 9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2). 10. Install the compressor clutch field coil connector (1) onto the connector bracket. 11. Reinstall the A/C compressor onto the engine if removed for A/C clutch service See: Service and Repair/A/C Compressor - Installation. 12. Connect the engine wire harness to the compressor clutch field coil connector. 13. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 14. Install the splash shield onto the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 15. Lower the vehicle. 16. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Diagrams Compressor Control Valve Assembly: Diagrams Connector (VDAC) - (ENGINE) 2 WAY SOLENOID-A/C COMPRESSOR (VDAC) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - Description Condenser HVAC: Description and Operation A/C Condenser - Description DESCRIPTION NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar. The A/C condenser (1) is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. The A/C condenser is equipped with mounting tabs (3), a tapping block for the A/C discharge and liquid lines (4) and a tapping block for the integral automatic transmission cooler (2), when equipped with an automatic transaxle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - Description > Page 7143 Condenser HVAC: Description and Operation A/C Condenser - Operation OPERATION When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C condenser has no serviceable parts. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is disconnected from the A/C condenser. The A/C condenser cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal Condenser HVAC: Service and Repair A/C Condenser - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Remove the nuts (5) that secure the A/C discharge line (1) and the A/C liquid line (4) to the tapping block (2) located on the right side of the A/C condenser. 4. Disconnect the A/C discharge and liquid lines from the tapping block and remove and discard the O-ring seals and gaskets. 5. Remove the bolt (3) that secures the tapping block to the right side of the radiator support. 6. Install plugs in, or tape over the opened refrigerant line fittings and condenser ports. NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar. 7. Remove the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Removal. 8. Remove the front bumper reinforcement See: Body and Frame/Bumper/Front Bumper/Front Bumper Reinforcement/Service and Repair/Front Bumper Reinforcement - Removal. 9. If equipped, disconnect the automatic transmission cooler lines (3) from the left side of the A/C condenser (2) See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 10. If equipped with the 2.0L diesel engine, remove the charge air cooler. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7146 11. Disengage the two plastic retaining tabs (1 and 4) that secure the top mounting brackets of the A/C condenser to the radiator. 12. Lift the A/C condenser slightly upward to disengage the two lower mounting brackets (5 and 6) from the condenser and remove the condenser from the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7147 Condenser HVAC: Service and Repair A/C Condenser - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: If only the A/C condenser is being replaced, add 10 milliliters (0.3 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar. 1. Position the A/C condenser (1) to the front of the engine compartment and engage the condenser to the two lower mounting brackets. 2. Engage the two plastic retaining tabs (1 and 4) that secure the top mounting brackets of the A/C condenser to the radiator. Make sure the retaining tabs are fully engaged. 3. If equipped, connect the automatic transmission cooler lines (2) to the left side of the A/C condenser See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. If equipped with the 2.0L diesel engine, install the charge air cooler. 5. Install the front bumper reinforcement See: Body and Frame/Bumper/Front Bumper/Front Bumper Reinforcement/Service and Repair/Front Bumper Reinforcement - Installation. 6. Install the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7148 7. Install the bolt (3) that secures the condenser tapping block (2) to the right side of the radiator support. Tighten the bolt securely. 8. Remove the tape or plug from the opened refrigerant line fittings and condenser ports. 9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 10. Connect the A/C liquid line (4) and the A/C discharge line (1) to the tapping block and install the retaining nuts (5). Tighten the nuts to 20 Nm (15 ft. lbs.). 11. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 12. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate 13. If the A/C condenser is being replaced, add 10 milliliters (0.3 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > A/C-Heater Control (3 Zone MTC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > A/C-Heater Control (3 Zone MTC) > Page 7153 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > A/C-Heater Control (3 Zone MTC) > Page 7154 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way Control Assembly: Diagrams A/C-Heater Control (ATC) (Instrument Panel) 32 Way Connector (ATC) - (INSTRUMENT PANEL) 32 WAY CONTROL-A/C-HEATER (ATC) - (INSTRUMENT PANEL) 32 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7157 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7158 Control Assembly: Diagrams A/C-Heater Control C1 (3 Zone MTC) (Instrument Panel) 16 Way Connector C1 (3 ZONE MTC) - (INSTRUMENT PANEL) 16 WAY CONTROL-A/C-HEATER (3 ZONE MTC) - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7159 Control Assembly: Diagrams A/C-Heater Control C1 (MTC) (Instrument Panel) 16 Way Connector C1 (MTC) - (INSTRUMENT PANEL) 16 WAY CONTROL-A/C-HEATER (MTC) - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7160 Control Assembly: Diagrams A/C-Heater Control C2 (MTC) (Instrument Panel) 5 Way Connector C2 (MTC) - (INSTRUMENT PANEL) 5 WAY CONTROL-A/C-HEATER (MTC) - (INSTRUMENT PANEL) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7161 Control Assembly: Diagrams A/C-Heater Control (ATC) (Instrument Panel) 32 Way Connector (ATC) - (INSTRUMENT PANEL) 32 WAY CONTROL-A/C-HEATER (ATC) - (INSTRUMENT PANEL) 32 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7162 A/C-Heater Control C1 (3 Zone MTC) (Instrument Panel) 16 Way Connector C1 (3 ZONE MTC) - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7163 CONTROL-A/C-HEATER (3 ZONE MTC) - (INSTRUMENT PANEL) 16 WAY A/C-Heater Control C1 (MTC) (Instrument Panel) 16 Way Connector C1 (MTC) - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7164 CONTROL-A/C-HEATER (MTC) - (INSTRUMENT PANEL) 16 WAY A/C-Heater Control C2 (MTC) (Instrument Panel) 5 Way Connector C2 (MTC) - (INSTRUMENT PANEL) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7165 CONTROL-A/C-HEATER (MTC) - (INSTRUMENT PANEL) 5 WAY A/C-Heater Control C3 (3 Zone MTC) (Instrument Panel) 16 Way Connector C3 (3 ZONE MTC) - (INSTRUMENT PANEL) 16 WAY CONTROL-A/C-HEATER (3 ZONE MTC) - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7166 A/C-Heater Control C4 (3 Zone MTC) (Instrument Panel) 8 Way Connector C4 (3 ZONE MTC) - (INSTRUMENT PANEL) 8 WAY CONTROL-A/C-HEATER (3 ZONE MTC) - (INSTRUMENT PANEL) 8 WAY Rear A/C-Heater Control (3 Zone HVAC) (Headliner) 8 Way Connector (3 ZONE HVAC) - (HEADLINER) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C-Heater Control (ATC) (Instrument Panel) 32 Way > Page 7167 CONTROL-A/C-HEATER-REAR (3 ZONE HVAC) - (HEADLINER) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone Control Assembly: Description and Operation Front - Manual Temperature Control (MTC) Single Zone MANUAL TEMPERATURE CONTROL (MTC) SINGLE ZONE The A/C-heater control for the front Manual Temperature Control (MTC) single zone system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. The heating-A/C system uses a dedicated microprocessor to drive the electrically operated door actuators. This control provides the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. The A/C-heater control (1) is located in the instrument panel and contains: - a rotary control for blower motor speed selection, and to turn the blower motor off (2). - a rotary control for temperature control of the discharged air (3). - a rotary control for mode control of the discharged air (4). - a push-button control with an indicator lamp to turn the rear window defogger system on and off (5). - a push-button control with an indicator lamp to turn the A/C system on and off (6). - a push-button control with an indicator lamp for recirculation control of the discharged air (7). The A/C-heater control for the MTC heating and A/C system and is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Prior to replacing an A/C-heater control, check for any Diagnostic Trouble Codes (DTCs) related to the heating-A/C system, and run the calibration procedure to verify that the concern is not an air-door calibration issue . See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test The A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7170 Control Assembly: Description and Operation Front - Automatic Temperature Control (ATC) Dual Zone AUTOMATIC TEMPERATURE CONTROL (ATC) DUAL ZONE The A/C-heater control for the Automatic Temperature Control (ATC) dual zone front heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. An infrared sensor located in the overhead console detects thermal radiation emitted by the front seat occupants and their surroundings. Based on the sensor input, the system automatically adjusts the air temperature, airflow volume, airflow distribution and amount of inside air recirculation to maintain front seat occupant comfort, even under changing outside weather conditions. All controls are identified by ISO graphic symbols. The ATC dual zone heating-A/C system uses a dedicated microprocessor to automatically drive the electrically operated door actuators. The ATC A/C-heater control obtains vehicle speed, engine speed, engine coolant temperature, ambient temperature and refrigerant system pressure. The ATC A/C-heater control communicates with other electrical modules in the vehicle over the Controller Area Network (CAN) IHC bus. This ATC system provides the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle and offers several manual override features such as fan speed, airflow distribution, defrost mode and when the outside air contains smoke, odors or high humidity, the interior air can be manually recirculated. The ATC dual zone A/C-heater control (1) is located in the instrument panel and contains: - a push button on/off control which allows the heating-A/C system to be completely turned off (2). The Vacuum-Fluorescent (VF) digital display (4) is blank when the heater-A/C system is off. - two rotary temperature controls to select both driver and front seat passenger comfort temperatures from 15° to 29° C (60° to 85° F) (3 and 5). Comfort temperatures for each zone are shown in the VF digital display. If the set temperatures are 15° C (60° F) and is adjusted lower, the A/C-heater control will attempt to achieve the lowest temperature possible, but the display will show LO. If the set temperatures are 29° C (85° F) and is adjusted up, the A/C-heater control will attempt to achieve the highest temperature possible, but the display will show HIGH. Temperatures can be displayed in either Metric or Fahrenheit. - a push button A/C on/off control (6). An ISO Snowflake symbol appears in the VF digital display when the A/C system is in operation, whether under manual or Auto mode. - a push button air recirculation control to set the heating-A/C system to Recirculation mode (7). An ISO Recirculation symbol appears in the VF digital display when Recirculation mode is selected and when the system exceeds 80 percent circulated air under Auto mode (due to high A/C demand). - a rocker switch mode control that can override the Auto mode (8). An ISO mode symbol appears in the VF digital display to indicate the current mode setting when selected manually or by Auto mode. - a push button rear window defogger on/off control (9). An indicator lamp illuminates in the control when selected. The indicator lamp illuminates in the control even with the heating-A/C system turned off. - a push button front window defogger control (10). An indicator lamp illuminates in the control when selected manually and an ISO symbol appears in the VF digital display when selected by auto mode. - a rocker switch fan speed control that can override the auto mode (11). A bar graph is shown in the VF digital display to indicate the selected or determined front fan speed (depending on manual or auto mode). - a push button automatic mode control to set the heating-A/C system to auto mode (12). AUTO appears in the VF digital display when the system is in auto mode. - illumination lamps for backlighting of the control. - computer logic that remembers the settings of the controls when the ignition is turned off and retains those settings after a restart. If the heating-A/C system is off when the ignition is turned off, the system will be off when the engine is restarted. - computer logic that provides variable air recirculation under high temperature and humidity conditions. Because recirculation is generally Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7171 accompanied by increased fan noise, the proportion of recirculated to outside air, gradually approaches full recirculation over a broad temperature range. The front A/C-heater control utilizes integrated circuitry and information carried on the CAN IHS bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allows it to control the electronic functions and features of the ATC heating-A/C system. The inputs received by the A/C-heater control of the ATC heating-A/C system are as follows: - Refrigerant Pressure - Evaporator Temperature - Engine Coolant Temperature - Ambient Air Temperature - Infrared Temperature Sensor - Vehicle Speed The messages broadcasted by the A/C-heater control of the ATC heating-A/C system are as follows: - A/C Request - A/C Select - Rear Window Defogger (EBL) Request The A/C-heater control for the ATC heating and A/C system is diagnosed using a scan toolSee: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Prior to replacing an A/C-heater control, check for any Diagnostic Trouble Codes (DTCs) related to the heating-A/C system, and run the calibration procedure to verify that the concern is not an air-door calibration issue See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged. The illumination lamps for the A/C-heater control can be serviced separately. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7172 Control Assembly: Description and Operation Front - Manual Temperature Control (MTC) Tri Zone MANUAL TEMPERATURE CONTROL (MTC) TRI ZONE The A/C-heater controls for the Manual Temperature Control (MTC) tri-zone heating-A/C system allows the driver, front seat passenger and the intermediate seat passengers, the ability to individually regulate air temperature as well as fan speed for their portion of the vehicle. Primary controls for the rear heating-A/C system are located on the front A/C-heater control panel. All controls are identified by ISO graphic symbols. FRONT CONTROL PANEL The front MTC dual zone A/C-heater control and integral computer (1) is located in the instrument panel and contains: - three rotary temperature controls (2, 7 and 9) to select the separate temperatures for both of the front comfort zones and the rear comfort zone - five push button mode controls (3 and 5) to select the position of the discharged air for the driver and front passenger comfort zones. An indicator lamp illuminates in each of the controls when selected. - a rotary control knob for front fan speed selection and turning the heater-A/C system off (4). - a push button air recirculation control (6). An indicator lamp illuminates in the control when selected. - a push button rear window defogger on/off control (8). An indicator lamp illuminates in the control when selected. The rear window defogger system operates and the indicator lamp illuminates in the control even when the heating-A/C system is turned off. - a rotary control knob for rear fan speed selection and turning the rear heater-A/C system off (10). This control has a position for locking out the rear heater-A/C controls, allowing only the driver and front seat passenger control of the rear heating-A/C system. - a push button A/C on/off control (11). An indicator lamp illuminates in the control when the A/C system is in operation. - computer logic that remembers the settings of the A/C-heater control when the ignition is turned off, and retains those settings after a restart. If the heating-A/C system is off when the ignition is turned off, the system will be off when the engine is restarted. The front A/C-heater control utilizes integrated circuitry and information carried on the Controller Area Network (CAN) IHS bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allows it to control the electronic functions and features of the MTC heating-A/C system. The front A/C-heater control is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Prior to replacing an A/C-heater control, check for any Diagnostic Trouble Codes(DTCs) related to the heating-A/C system, and run the calibration procedure to verify that the concern is not an air-door calibration issue See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The front A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged. REAR CONTROL PANEL The rear MTC A/C-heater control is located in the headliner and allows intermediate seat passengers to adjust rear air distribution, temperature and blower motor speed when the rear heating-A/C system primary on/off control in the front A/C-heater control in the instrument panel is set to the on position and the rear heater-A/C controls are NOT locked out by the driver or front seat passenger. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7173 The rear A/C-heater control (1) contains: - a rotary control knob for fan speed selection and turning the rear heating-A/C system on and off (2). - a rotary control knob for temperature control of the rear discharged air (3). An indicator lamp illuminates in the control when the rear heater-A/C controls are locked out by the driver or front seat passenger. - a rotary control knob for mode control of the rear discharged air (4). The rear A/C-heater control is a slave potentiometer to the front A/C-heater control and cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7174 Control Assembly: Description and Operation Front - Automatic Temperature Control (ATC) Tri Zone AUTOMATIC TEMPERATURE CONTROL (ATC) TRI ZONE The A/C-heater controls for the Automatic Temperature Control (ATC) tri-zone heating-A/C system allows the driver, font seat passenger and the intermediate seat passengers the ability to individually regulate the air temperature for their portion of the vehicle automatically. Primary controls for the rear are located on the front A/C-heater control panel. All controls are identified by ISO graphic symbols. FRONT CONTROL PANEL The front A/C-heater control (1) and integral computer is located in the instrument panel and contains: - three rotary temperature controls (2) to select both of the front and the rear comfort temperatures from 15° to 29° C (60° to 85° F). Comfort temperatures for each zone are shown in the Vacuum-Fluorescent (VF) digital display (5). If the set temperatures are 15° C (60° F) and is adjusted lower, the A/C-heater control will attempt to achieve the lowest temperature possible, but the display will show LO. If the set temperatures are 29° C (85° F) and is adjusted up, the A/C-heater control will attempt to achieve the highest temperature possible, but the display will show HIGH. Temperatures can be displayed in either Metric or Fahrenheit, which is selected from the overhead console. - a rocker switch front fan speed control (3) that can override the Auto mode. A bar graph is shown in the VF digital display to indicate the selected or determined front fan speed (depending on manual or Auto mode). - a push button front window defogger control (4). An indicator lamp illuminates in the control when selected manually and an ISO symbol appears in the VF digital display when selected by Auto mode. - a push button air recirculation control (6). An indicator lamp illuminates in the control when selected manually and an ISO Recirculation symbol appears in the VF digital display when the system exceeds 80 percent circulated air under Auto mode due to high A/C demand. - a rocker switch front mode control (7) that can override the Auto mode. An ISO mode symbol appears in the VF digital display to indicate the current mode setting when selected manually or by Auto mode. - a push button A/C on/off control (8). An ISO Snowflake symbol appears in the VF digital display when the A/C system is in operation, whether under manual or Auto mode. - a push button automatic mode control (9) to set the heating-A/C system to Auto mode. FRONT AUTO appears in the VF digital display when the system is in Auto mode. - a rocker switch rear mode control (10) that can override the rear A/C-heater control and the Auto mode. An ISO mode symbol appears in the center portion of the VF display to show the current mode setting when selected manually or by Auto mode. - a push button control that locks out the rear heater-A/C controls (11), allowing only the driver and front seat passenger control of the rear heating-A/C system. An indicator lamp illuminates in the control when selected. - a push button on/off control (12) that turns the rear heating-A/C system completely off. The center portion of the VF display is blank when the rear heating-A/C system is off. - a push button rear window defogger on/off control (13). An indicator lamp illuminates in the control when selected. The indicator lamp illuminates in the control even with the heating-A/C system turned off. - a rocker switch rear fan speed control (14) that can override the rear A/C-heater control and the Auto mode. A bar graph is shown in the center portion of the VF digital display to indicate the selected or determined rear fan speed (depending on manual or Auto mode). - a push button synchronize control (15) that synchronizes the temperature of all three of the comfort zones to the drivers selected temperature. SYNC appears in the VF digital display when the system is synchronized, whether under manual or Auto mode. - a push button on/off control (16) which allows the heating-A/C system to be completely turned off. The display is blank when the heater-A/C system is off. - illumination lamps for backlighting of the control. - computer logic that remembers the settings of the controls when the ignition is turned off and retains those settings after a restart. If the system is off when the ignition is turned off it will be off when the engine is restarted, etc. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7175 - computer logic that provides variable air recirculation under high temperature and humidity conditions. Because recirculation is generally accompanied by increased fan noise, the proportion of recirculated to outside air gradually approaches full recirculation over a broad temperature range. The front A/C-heater control utilizes integrated circuitry and information carried on the Controller Area Network (CAN) IHS bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allows it to control the electronic functions and features of the ATC heating-A/C system. The inputs received by the A/C-heater control of the ATC heating-A/C system are as follows: - Refrigerant Pressure - Evaporator Temperature - Engine Coolant Temperature - Ambient Air Temperature - Infrared Temperature Sensor - Vehicle Speed The messages broadcast by the A/C-heater control of the ATC heating-A/C system are as follows: - A/C Request - A/C Select - Rear Window Defogger (EBL) Request - Heated Front Seat Requests The front A/C-heater control is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Prior to replacing an A/C-heater control, check for any Diagnostic Trouble Codes (DTCs) related to the heating-A/C systems and run the calibration procedure to verify that the concern is not an system calibration issue See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The front A/C-heater control cannot be repaired and must be replaced if inoperative or damaged. REAR CONTROL PANEL The rear A/C-heater control is located in the rear overhead console and allows intermediate seat passengers to adjust rear air distribution, temperature and blower motor speed when the rear heating-A/C system primary on/off control in the front A/C-heater control in the instrument panel is set to the on position and the rear heater-A/C controls are NOT locked out by the driver and front seat passenger. The rear A/C-heater control (1) contains: - a rotary control knob for fan speed selection and turning the rear heating-A/C system off or to Auto mode (2). - a rotary control knob for temperature control of the rear discharged air (3). An indicator lamp illuminates in the control when the rear heater-A/C controls are locked out by the driver or front seat passenger. - a rotary control knob for mode control of the rear discharged air (4). The rear A/C-heater control is a slave potentiometer to the front A/C-heater control and cannot be repaired and must be replaced if inoperative or Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7176 damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7177 Control Assembly: Description and Operation Rear DESCRIPTION The A/C-heater controls allows the driver and front seat passenger and the intermediate seat passengers the ability to regulate air temperature as well as fan speed for the rear heating-A/C system and provides a floor outlet near the right rear door and upper air outlets at the ceiling. All controls are identified by ISO graphic symbols. The primary controls for the rear heating-A/C system are located in the instrument panel See: . The rear A/C-heater control is located in the headliner and allows intermediate seat passengers to adjust rear air distribution, temperature and blower motor speed when the rear heating-A/C system primary on/off control in the instrument panel is set to the on position and the rear heater-A/C controls are NOT locked out by the driver and front seat passenger. The rear automatic temperature control (ATC) A/C-heater control (1) contains: - a rotary control knob for fan speed selection and turning the rear heating-A/C system off or to Auto mode (2). - a rotary control knob for temperature control of the rear discharged air (3). An indicator lamp illuminates in the control when the rear heater-A/C controls are locked out by the driver or front seat passenger. - a rotary control knob for mode control of the rear discharged air (4). The rear manual temperature control (MTC) A/C-heater control (1) contains: - a rotary control knob for fan speed selection and turning the rear heating-A/C system on and off (2). - a rotary control knob for temperature control of the rear discharged air (3). An indicator lamp illuminates in the control when the rear heater-A/C controls are locked out by the driver or front seat passenger. - a rotary control knob for mode control of the rear discharged air (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Temperature Control (MTC) Single Zone > Page 7178 The rear A/C-heater control is a slave potentiometer to the front A/C-heater control and is diagnosed using a scan tool. Prior to replacing an A/C-heater control, check for any diagnostic trouble codes (DTCs) related to the heating-A/C systems and run the calibration procedure to verify that the concern is not a system issue, See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The rear A/C-heater control cannot be repaired must be replaced if inoperative or damaged. The illumination lamps are available for service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal Control Assembly: Service and Repair A/C and Heater Control - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel center bezel from cosmetic damage during this service procedure. NOTE: MTC single zone A/C-heater control shown. Other A/C-heater controls similar. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel (3) and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws (2 and 4) that secure the A/C-heater control (1) to the back of the center bezel and remove the control. Rear REMOVAL NOTE: Take the proper precautions to protect the face of the rear A/C-heater control bezel from cosmetic damage during this service procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7181 1. Disconnect and isolate the negative battery cable. 2. Remove the rear A/C-heater control (3) and bezel (1) as an assembly from the headliner by releasing the four metal retaining tabs (2) using Trim Stick C-4755 or equivalent. 3. Disconnect the wire harness connector from the back of the rear A/C-heater control and place the control and bezel assembly on a workbench. 4. Remove the two screws (4) that secure the rear A/C-heater control to the rear control bezel and remove the control from the bezel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7182 Control Assembly: Service and Repair A/C and Heater Control - Installation Front INSTALLATION NOTE: MTC single zone A/C-heater control shown. Other A/C-heater controls similar. 1. Position the A/C-heater control (1) onto the back of the center bezel (3). 2. Install the screws (2 and 4) that secure the A/C-heater control to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel Installation. 4. Reconnect the negative battery cable. NOTE: The A/C-heater control will automatically perform the Actuator Calibration function when the ignition is initially turned on when installing a new control or when reinstalling the original control. However, the Actuator Calibration function must be manually initiated using a scan tool if the A/C-heater control has been previously installed in another vehicle. 5. If required, initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION 1. Position the rear A/C-heater control (3) to the rear control bezel (1) and align the control to the two plastic guide posts on the back of the bezel. 2. Install the two screws (4) that secure the rear A/C-heater control to the rear control bezel. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector to the back of the rear A/C-heater control and install the bezel and control as an assembly to the headliner. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7183 Make sure the four metal retaining tabs (2) are fully engaged. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF Control Module HVAC: Customer Interest A/C - Airflow From Vents With A/C OFF NUMBER: 24-008-08 GROUP: Air Conditioning DATE: September 4, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.01 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Airflow Through HVAC Ducts with System Off OVERVIEW: This Bulletin involves reprogramming the Three Zone Manual Temperature Control module with new software. MODELS: 2008 (RT) Grand Caravan/Town & Country 2009 (JC) Journey NOTE: This bulletin applies to RT equipped with 3 zone manual A/C (Sales Code HAG) built prior to April 16, 2008 (MDH0416XX) at Windsor Assembly plant (R in 11th VIN position) -OR- April 22, 2008 (MDH0422XX) at the St. Louis Assembly plant (B in 11th VIN position) NOTE: This bulletin applies to JC equipped with 3 zone manual A/C (Sales Code HAG) built before June 15, 2008 (MDH0615XX). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is noticeable while driving with the HVAC system off. This may be more noticeable with the temperature settings at medium or higher heat settings due to the temperature differential coming out of the ducts. Turning the blower on, and then off will force the fresh air/recirculation door closed eliminating the airflow. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C Systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 9.01 level software or higher. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7192 software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home" screen: a.Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7193 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF Control Module HVAC: All Technical Service Bulletins A/C - Airflow From Vents With A/C OFF NUMBER: 24-008-08 GROUP: Air Conditioning DATE: September 4, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.01 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Airflow Through HVAC Ducts with System Off OVERVIEW: This Bulletin involves reprogramming the Three Zone Manual Temperature Control module with new software. MODELS: 2008 (RT) Grand Caravan/Town & Country 2009 (JC) Journey NOTE: This bulletin applies to RT equipped with 3 zone manual A/C (Sales Code HAG) built prior to April 16, 2008 (MDH0416XX) at Windsor Assembly plant (R in 11th VIN position) -OR- April 22, 2008 (MDH0422XX) at the St. Louis Assembly plant (B in 11th VIN position) NOTE: This bulletin applies to JC equipped with 3 zone manual A/C (Sales Code HAG) built before June 15, 2008 (MDH0615XX). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is noticeable while driving with the HVAC system off. This may be more noticeable with the temperature settings at medium or higher heat settings due to the temperature differential coming out of the ducts. Turning the blower on, and then off will force the fresh air/recirculation door closed eliminating the airflow. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C Systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 9.01 level software or higher. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7199 software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home" screen: a.Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7200 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7201 Control Module HVAC: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7202 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way Control Module HVAC: Diagrams Front Blower Module (ATC) (Instrument Panel) 4 Way Connector (ATC) - (INSTRUMENT PANEL) 4 WAY MODULE-BLOWER-FRONT (ATC) - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way > Page 7205 Control Module HVAC: Diagrams Rear Blower Module C1 (3 Zone ATC) (Body) 6 Way Connector C1 (3 ZONE ATC) - (BODY) 6 WAY MODULE-BLOWER-REAR (3 ZONE ATC) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way > Page 7206 Control Module HVAC: Diagrams Rear Blower Module C2 (3 Zone ATC) (Body) 2 Way Connector C2 (3 ZONE ATC) - (BODY) 2 WAY MODULE-BLOWER-REAR (3 ZONE ATC) - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description Control Module HVAC: Description and Operation Front Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module . The blower motor power module is mounted to the bottom of the HVAC housing, on the passenger side of the vehicle. The blower motor power module consists of a molded plastic mounting plate (1) with an integral connector receptacle (2). Concealed behind the mounting plate is the power module electronic circuitry (3) and a finned aluminum heat sink (4). The blower motor power module is accessed for service from under the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7209 Control Module HVAC: Description and Operation Front Blower Motor Power Module - Operation OPERATION The blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the instrument panel wire harness. A second lead and connector of the instrument panel wire harness is connected to the blower motor. The blower motor power module allows the microprocessor-based automatic temperature control(ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7210 Control Module HVAC: Description and Operation Rear Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) rear heating-A/C system. Models equipped with the manual temperature control (MTC) rear heating-A/C system use a blower motor resistor, instead of the blower motor power module . The rear blower motor power module (1) is mounted to the inboard side of the rear heating-A/C housing, located on the right side of the vehicle. The rear blower motor power module consists of a molded plastic housing with two integral wire connector receptacles (2) for the power module electronic circuitry, a mounting plate (3) with a gasket and a finned aluminum heat sink (4). The rear blower motor power module can be accessed for service without removing the rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7211 Control Module HVAC: Description and Operation Rear Blower Motor Power Module - Operation OPERATION The rear blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the rear body wire harness. A second lead and connector of the wire harness is connected to the rear blower motor. The rear blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the rear blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The rear blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal Control Module HVAC: Service and Repair Front Blower Motor Power Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heat sink for the blower motor power module may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor power module, wait five minutes to allow the heat sink to cool before performing diagnosis or service. Failure to take this precaution may result in possible serious injury. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the blower motor power module (2) located at the bottom of the HVAC housing (3) on the passenger side of the vehicle. 3. Remove the two screws (4) that secure the blower motor power module to the HVAC housing and remove the power module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7214 Control Module HVAC: Service and Repair Front Blower Motor Power Module - Installation INSTALLATION NOTE: LHD model shown. 1. Position the blower motor power module (2) into the bottom of the HVAC housing (3). 2. Install the two screws (4) that secure the blower motor power module to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor power module. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7215 Control Module HVAC: Service and Repair Rear Blower Motor Power Module - Installation INSTALLATION 1. Position the rear blower motor power module (3) onto the rear heater-A/C housing (2). 2. Install the two screws (1) that secure the rear blower motor power module to the rear heater-A/C housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the two wire harness connectors (4) to the rear blower motor power module. 4. Install the right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7216 Control Module HVAC: Service and Repair Rear Blower Motor Power Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the two wire harness connectors (4) from the rear blower motor power module (3). 4. Remove the two screws (1) that secure the rear blower motor power module to the rear heater-A/C housing (2) and remove the module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description Evaporator Core: Description and Operation Front A/C Evaporator - Description DESCRIPTION NOTE: LHD model shown. The A/C evaporator (1) for the heating-A/C system is mounted in the HVAC housing, which is located behind the instrument panel. The A/C evaporator and its insulator (2) are positioned within the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. A tapping block (3) and O-ring seals (4) are used to connect and seal the A/C evaporator tubes (5) to the A/C expansion valve. The A/C evaporator can only be serviced by removing and disassembling the HVAC housing assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description > Page 7221 Evaporator Core: Description and Operation Front A/C Evaporator - Operation OPERATION Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C expansion valve is removed from the A/C evaporator. The A/C evaporator cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description > Page 7222 Evaporator Core: Description and Operation Rear A/C Evaporator - Description DESCRIPTION The rear A/C evaporator (4) is located within the rear heater-A/C housing, behind the right interior quarter panel trim. The rear A/C evaporator is positioned in the rear heater-A/C housing so that all air entering the housing must pass over the evaporator fins (3) before it is distributed through the rear heating-A/C system ducts and outlets. However, air passing over the rear evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator. The A/C expansion valve is connected and sealed to the A/C evaporator tubes (2) by use of rubber O-ring seals and a tapping plate (1). The rear A/C evaporator can only be serviced by removing and disassembling the rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description > Page 7223 Evaporator Core: Description and Operation Rear A/C Evaporator - Operation OPERATION Refrigerant enters the rear A/C evaporator from the rear A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the rear A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the rear A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the rear A/C expansion valve is removed from the rear A/C evaporator. The rear A/C evaporator cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal Evaporator Core: Service and Repair Front A/C Evaporator - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The HVAC housing assembly must be removed from vehicle and disassembled for service of the A/C evaporator. NOTE: LHD model shown. 1. Remove the HVAC housing and place it on a workbench . 2. Disassemble the HVAC housing to gain access to the A/C evaporator See: Housing Assembly HVAC/Service and Repair/Overhaul/Disassembly. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced. 3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7226 Evaporator Core: Service and Repair Front A/C Evaporator - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: If only the A/C evaporator is being replaced, add 10 milliliters (0.3 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown. NOTE: Make sure that the foam insulator is properly positioned around the A/C evaporator and in the HVAC housing. 1. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 2. Assemble the HVAC housing See: Housing Assembly HVAC/Service and Repair/Overhaul/Assembly. 3. Install the HVAC housing . 4. If the A/C evaporator is being replaced, add 10 milliliters (0.3 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7227 Evaporator Core: Service and Repair Rear A/C Evaporator - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Removal. 3. Remove the foam seal (2) from the flange (1) located at the bottom of the rear heater-A/C housing (3). If the foam seal is deformed or damaged, it must be replaced. 4. Remove the three screws (2) that secure the flange (1) to the bottom of the rear heater-A/C housing (3) and remove the flange. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7228 5. Remove the two screws (1) that secure the rear expansion valve (3) to the tapping plate located on the end of the rear evaporator tubes (2) and remove the valve. 6. Remove and discard the O-ring seals and install plugs in, or tape over the opened evaporator tubes and expansion valve ports. 7. Remove the wire harness connector (7) from the lower rear heater-A/C housing (6). 8. Open the evaporator tube retaining bracket (3) located on the outboard side of the lower housing. 9. Remove the metal retaining clip (2) that secures the lower housing to the rear heater-A/C housing (4). 10. Remove the five screws (1 and 5) that secure the lower housing the rear heater-A/C housing and carefully remove the lower housing. Rotate and tilt the lower housing as necessary for removal. 11. Remove the screw (1) that secures the rear evaporator cover (3) to the outboard side of the rear heater-A/C housing (2) and remove the cover of the housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7229 12. Carefully pull the rear A/C evaporator (4) out the bottom of the rear heater-A/C housing (3). Guide the evaporator tubes (2) past the heater core tubes (1). If the foam seals on the A/C evaporator are deformed or damaged, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7230 Evaporator Core: Service and Repair Rear A/C Evaporator - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level . NOTE: If only the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak. 1. Install the rear A/C evaporator (4) into the rear heater-A/C housing (3). Guide the evaporator tubes (2) past the rear heater core tubes (1). Make sure that the foam seals are properly installed on the evaporator. 2. Install the evaporator cover (3) onto the outboard side of the rear heater-A/C housing (2) and install the retaining screw (1). Tighten the screw to 1.2 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7231 3. Install the lower rear heater-A/C housing (6) onto the rear heater-A/C housing (4). Rotate and tilt the lower housing as necessary for installation. 4. Install the five screws (1 and 5) that secure the lower housing to the rear heater-A/C housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 5. Install the metal retaining clip (2) that secures the lower housing to the rear heater-A/C housing. 6. Close the evaporator tube retaining bracket (3). Make sure the bracket retainers are fully engaged. 7. Install the wire harness connector (7) onto the lower rear heater-A/C housing. 8. Remove the tape or plugs from the rear evaporator tubes and expansion valve ports. 9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 10. Install the rear A/C expansion valve (3) onto the tapping plate located on the end of the rear evaporator tubes (2) 11. Install two bolts (1) that secure the rear A/C expansion valve to the taping plate. Tighten the bolts to 11 Nm (97 in. lbs.). 12. Position the flange (1) to the bottom of the rear heater-A/C housing (3) and install the three retaining screws (2). Tighten the screws to 1.2 Nm (10 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7232 in. lbs.). 13. Install the foam seal (2) onto the flange (1) at the bottom of the rear heater-A/C housing (3). Make sure that the foam seal is properly installed. 14. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 15. Reconnect the negative battery cable. 16. If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7236 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7237 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7238 Evaporator Temperature Sensor / Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SENSOR-EVAPORATOR TEMPERATURE - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description > Page 7241 Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing See: Compressor HVAC/Description and Operation/A/C Compressor - Operation. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal > Page 7244 Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > A/C Expansion Valve - Description Expansion Valve: Description and Operation A/C Expansion Valve - Description Front DESCRIPTION The A/C expansion valve controls the amount of refrigerant entering the A/C evaporator. The A/C expansion valve is of a thermostatic expansion valve (TXV) design and consists of an aluminum H-valve type body (1) with an inlet port (2), outlet port (3) and an integral thermal sensor (4). The A/C expansion valve is located in the engine compartment at the dash panel, between the A/C refrigerant lines and the A/C evaporator. Rear DESCRIPTION The rear A/C expansion valve controls the amount of refrigerant entering the rear A/C evaporator. The rear A/C expansion valve is of a thermostatic expansion valve (TXV) design and consists of an aluminum H-valve type body (1) with an inlet port (2), outlet port (3) and an integral thermal sensor (4). The rear A/C expansion valve is located on the bottom of the rear heater-A/C housing, which extends through the rear floor panel behind the right rear wheel housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > A/C Expansion Valve - Description > Page 7249 Expansion Valve: Description and Operation A/C Expansion Valve - Operation Front OPERATION The A/C expansion valve controls the high-pressure, low temperature liquid refrigerant from the A/C liquid line and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the A/C evaporator. A mechanical sensor in the A/C expansion valve monitors the temperature and pressure of the refrigerant leaving the A/C evaporator through the A/C suction line, and adjusts the orifice size at the liquid line port to let the proper amount of refrigerant into the evaporator to meet the vehicle A/C cooling requirements. Controlling the refrigerant flow through the A/C evaporator ensures that none of the refrigerant leaving the A/C evaporator is still in a liquid state, which could damage the A/C compressor. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected from the expansion valve, or if the expansion valve is removed. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. The A/C expansion valve is factory calibrated and cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear A/C expansion valve controls the flow of high-pressure, low temperature liquid refrigerant entering the expansion valve and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the rear A/C evaporator. To meet the vehicles A/C cooling requirements, a mechanical sensor is used in the rear A/C expansion valve to monitor the temperature and pressure of the refrigerant leaving the rear A/C evaporator and then adjust the inlet port orifice size to allow only the proper amount of refrigerant to enter the evaporator. Controlling the refrigerant flow through the rear A/C evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the A/C compressor. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected from the expansion valve, or if the expansion valve is removed. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. The rear A/C expansion valve is factory calibrated and cannot be adjusted or repaired and must be replaced if inoperative or damaged See: Testing and Inspection. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 7250 Expansion Valve: Testing and Inspection A/C EXPANSION VALVE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The A/C expansion valve should only be tested following testing of the A/C compressor. NOTE: Liquid CO2 is required to test the A/C expansion valve. This material is available from most welding supply facilities. Liquid CO2 is also available from companies which service and sell fire extinguishers. When testing the A/C expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve: 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment. 3. Set the A/C-heater controls so that the A/C compressor is operating, the temperature control is in the highest temperature position, the mode-air doors is directing air output to the floor and the blower motor operating is operating at the highest speed. 4. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the A/C evaporator. 5. If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 827 kPa to 1655 kPa (120 psi to 240 psi). The suction (low pressure) gauge should read 207 kPa to 345 kPa (30 psi to 50 psi). If OK, go to 6. If not OK, replace the inoperative A/C expansion valve. WARNING: Protect the skin and eyes from exposure to liquid CO2 or personal injury can result. 6. If the suction (low pressure) gauge reads within the specified range, freeze the A/C expansion valve for 30 seconds using liquid CO2 or another suitable super-cold material. Do not spray R-134a or R-12 refrigerant on the A/C expansion valve for this test. The suction (low pressure) gauge reading should drop by 69 kPa (10 psi). If OK, go to 7. If not OK, replace the inoperative A/C expansion valve. 7. Allow the expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 207 kPa to 345 kPa (30 psi to 50 psi). If not OK, replace the inoperative A/C expansion valve. 8. When expansion valve testing is complete, test the overall A/C system performance See: Testing and Inspection/Component Tests and General Diagnostics. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal Expansion Valve: Service and Repair A/C Expansion Valve - Removal Front REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: LHD model shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required. 4. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7253 5. Remove the nut (6) that secures the A/C liquid and suction line assembly (1) to the stud (2) located on the right front shock tower. 6. Remove the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve (4). 7. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve, remove and discard the O-ring seals and position the refrigerant lines out of the way. 8. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block (3). 9. Remove the A/C expansion valve from the tapping block and remove and discard the O-ring seals 10. Install plugs in, or tape over the opened refrigerant fittings and all expansion valve and evaporator tube ports. Rear REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7254 1. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 2. Raise and support the vehicle. 3. Loosen the nuts (1) that secure the underbody refrigerant lines to the underbody refrigerant extension lines (2 and 6) located behind the right rear wheel housing. 4. Disconnect the underbody refrigerant lines from underbody refrigerant extension lines and remove and discard the O-ring seals. 5. Remove the nut (5) that secures the underbody refrigerant extension line sealing plate (4) to the rear A/C expansion valve (3). 6. Disconnect the underbody refrigerant extension lines and sealing plate from the rear A/C expansion valve and remove and discard the O-ring seals. NOTE: Illustration shown with rear heater-A/C housing removed from vehicle. 7. Remove the two bolts (1) that secure the rear A/C expansion valve (3) to the rear evaporator tubes (2), which extend through the rear floor panel behind the right rear wheel housing. 8. Remove the rear A/C expansion valve from the rear evaporator tubes and remove and discard the O-ring seals. 9. Install plugs in, or tape over all the opened underbody refrigerant line fittings and the rear evaporator and expansion valve ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7255 Expansion Valve: Service and Repair A/C Expansion Valve - Installation Front INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected from the expansion valve, or if the expansion valve is removed. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. NOTE: LHD model shown in illustrations. 1. Remove the tape or plugs from the opened refrigerant fittings and all expansion valve and evaporator ports. 2. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line and evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3) 4. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 Nm (97 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7256 5. Connect the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 6. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 7. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 8. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). 9. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 10. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7257 11. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 12. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Rear INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected from the expansion valve, or if the expansion valve is removed. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. NOTE: Illustration shown with rear heater-A/C housing removed from vehicle. 1. Remove the tape or plugs from the opened underbody refrigerant line fittings and the rear evaporator and expansion valve ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Install the rear A/C expansion valve (3) onto the rear evaporator tubes (2) extending through the rear floor panel behind the right rear wheel housing. 4. Install two bolts (1) that secure the rear A/C expansion valve to the rear evaporator tubes. Tighten the bolts to 11 Nm (97 in. lbs.). 5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant extension line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7258 CAUTION: Use care when installing the underbody refrigerant extension lines to the rear A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the sealing plate retaining nut or damage to the sealing rings and tube ends may occur. 6. Connect the underbody refrigerant extension lines (2 and 6) and the sealing plate (4) to the rear A/C expansion valve (2). 7. Loosely install the nut (5) that secures the extension lines and sealing plate to the rear A/C expansion valve. 8. Connect the underbody refrigerant lines to the underbody refrigerant extension lines and tighten the fitting nuts (1) to 23 Nm (17 ft. lbs.). 9. Tighten the nut that secures the extension lines and sealing plate to the rear A/C expansion valve to 11 Nm (97 in. lbs.). 10. Lower the vehicle. 11. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 12. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 13. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description Heater Core: Description and Operation Front Heater Core - Description DESCRIPTION NOTE: LHD model shown. The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins and is positioned within the air distribution housing so that only the selected amount of air entering the housing passes through the heater core before it is distributed through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes (3). The heater core can only be serviced by removing the HVAC housing from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 7263 Heater Core: Description and Operation Front Heater Core - Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 7264 Heater Core: Description and Operation Rear Heater Core - Description DESCRIPTION The rear heater core (1) is located in the rear heater-A/C housing behind the right interior quarter trim panel. The rear heater core is a heat exchanger made of rows of tubes and fins (2). The heater core tubes (3) are permanently soldered to the heater core tank and are retained to the outboard side of the rear heater-A/C housing by use of an integral bracket (4) and screw. The rear heater-A/C housing must be removed from the vehicle to service the rear heater core. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 7265 Heater Core: Description and Operation Rear Heater Core - Operation OPERATION Engine coolant is circulated through heater hoses and tubes to the rear heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and the air directed through the heater core picks up the heat from the fins. The rear blend-air door allows control of the rear heater output air temperature by controlling the amount of air flowing through or around the rear heater core. The rear blower motor speed controls the volume of air flowing through the rear heater-A/C housing. The rear heater core cannot be repaired and must be replaced if inoperative, leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal Heater Core: Service and Repair Front Heater Core - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core. NOTE: LHD model with A/C shown. Heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench . 2. Remove the left side front floor duct See: Air Duct/Service and Repair/Floor Distribution Duct - Removal. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (5). 4. Remove the screw (6) that secures the flange to the front of the HVAC housing and remove the flange. 5. On RHD models, remove the air distribution housing from the HVAC housing 6. Carefully pull the heater core (4) out of the driver side of the air distribution housing (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7268 Heater Core: Service and Repair Front Heater Core - Installation INSTALLATION NOTE: LHD model with A/C shown. 1. Carefully install the heater core (4) into the side of the air distribution housing (3). 2. On RHD models, install the air distribution housing onto the HVAC housing (5) . 3. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 4. Install the screw (6) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 5. Install the foam seal (1) onto the flange. 6. Install the left side front floor duct See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 7. Install the HVAC housing assembly . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7269 Heater Core: Service and Repair Rear Heater Core - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Removal. 3. Remove the foam seal (2) from the flange (1) located at the bottom of the rear heater-A/C housing (3). If the foam seal is deformed or damaged, it must be replaced. 4. Remove the three screws (2) that secure the flange (1) to the bottom of the rear heater-A/C housing (3) and remove the flange. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7270 5. Disconnect the wire harness connector (3) from the rear blend door actuator (2) located on the outboard side of the rear heater-A/C housing (4). 6. Remove the two screws (1) that secure the rear blend door actuator to the rear heater-A/C housing and remove the actuator. 7. Disconnect the wire harness connector (1) from the rear mode door actuator (3) located on the outboard side of the rear heater-A/C distribution housing (2). 8. Remove the three metal retaining clips (4) that secure the rear distribution housing to the rear heater-A/C housing (5). 9. Release the five plastic retaining tabs (4) that secure the rear distribution housing and rear heater-A/C housing together and separate the housings. 10. Remove the screw (1) that secures the rear heater core tubes (3) to the outboard side of the rear heater-A/C housing (4). CAUTION: To prevent damage to the plastic evaporator tube bracket, carefully guide the heater core tubes past the bracket during removal of the heater core. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7271 11. Carefully pull the rear heater core (5) out of the top of the rear heater-A/C housing. Guide the heater core tubes past the plastic evaporator tube bracket (2). If the foam seals on the heater core are deformed or damaged, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7272 Heater Core: Service and Repair Rear Heater Core - Installation INSTALLATION CAUTION: To prevent damage to the plastic evaporator tube bracket, carefully guide the heater core tubes past the bracket during installation of the heater core. 1. Carefully install the rear heater core (5) into the rear heater-A/C housing (4). Guide the heater core tubes past the plastic evaporator tube bracket (2). Make sure that the foam seals are properly installed. 2. Install the screw (1) that secures the rear heater core tubes (3) to the outboard side of the rear heater-A/C housing. Tighten the screw to 1.2 Nm (10 in. lbs.). 3. Position the rear heater-A/C distribution housing (2) to the rear heater-A/C housing (5) and engage the five plastic retaining tabs (4). Make sure the retaining tabs are fully engaged. 4. Install the three metal retaining clips (6) that secure the rear distribution housing to the rear heater-A/C housing. 5. Connect the wire harness connector (1) to the rear mode door actuator (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7273 6. Position the rear blend door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear blend-air door pivot shaft (2). 7. Install the two screws (1) that secure the rear blend door actuator (2) to the rear heater-A/C housing (4). Tighten the screws to 1.2 Nm (10 in. lbs.). 8. Connect the wire harness connector (3) to the rear blend door actuator. 9. Position the flange (1) to the bottom of the rear heater-A/C housing (3) and install the three retaining screws (2). Tighten the screws to 1.2 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7274 10. Install the foam seal (2) onto the flange (1) at the bottom of the rear heater-A/C housing (3). Make sure that the foam seal is properly installed. 11. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Installation. 12. Reconnect the negative battery cable. 13. If the rear heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 14. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 15. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > High Pressure Relief Valve - Operation High Pressure Safety Valve HVAC: Description and Operation High Pressure Relief Valve Operation HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve should not open when the A/C system is operating correctly. If the high pressure relief valve vents refrigerant, there is most likely a problem within the A/C refrigerant system. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. If the high pressure relief valve vents refrigerant, see the A/C System Diagnosis chart See: Testing and Inspection/Component Tests and General Diagnostics. The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description Hose/Line HVAC: Description and Operation A/C Discharge Line - Description DESCRIPTION NOTE: 2.7L shown. Other engines similar. The A/C discharge line (2) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the metal gaskets (1) and rubber O-ring seals (3) used on the fittings. The O-ring seals are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is disconnected. The A/C discharge line cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7283 Hose/Line HVAC: Description and Operation A/C Liquid Line - Description DESCRIPTION NOTE: A/C liquid and suction line assembly with rear A/C shown. Front A/C only line assembly similar. The A/C liquid line is serviced in two sections. The front section of the A/C liquid line is the refrigerant line that carries liquid refrigerant from the A/C condenser to the A/C receiver/drier and is only serviced as an assembly with receiver/drier See: Receiver Dryer/Description and Operation/Front A/C Receiver Drier - Description. The rear section of the A/C liquid line (1) carries liquid refrigerant from the A/C receiver/drier to the A/C expansion valve and includes the high side service port (2) and a fitting for the A/C pressure transducer (4). The rear section of the A/C liquid line is only serviced as an assembly with the A/C suction line (5). When equipped with rear A/C, the A/C liquid and suction line assembly includes connections for the underbody refrigerant lines (3). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid and suction line assembly has no serviceable parts except for the metal gaskets, rubber O-ring seals and the service port valve cores. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is disconnected. The A/C liquid and suction line assembly cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7284 Hose/Line HVAC: Description and Operation A/C Suction Line - Description DESCRIPTION NOTE: A/C Suction line for 2.7L engine shown. Other engines similar. The A/C suction line carries refrigerant from the A/C expansion valve to the A/C compressor and is serviced in two sections. The upper section of the A/C suction line (1) includes the low side service port (2) and is only serviced as an assembly with the rear A/C liquid line (6). When equipped with rear A/C, the A/C liquid and suction line assembly includes connections for the underbody refrigerant lines (3). The lower section of the A/C suction line (7) connects to the upper section of the suction line and the connections are sealed by use of metal gaskets (5) and rubber O-ring seals (4) NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The lower A/C suction line and the A/C liquid and suction line assembly has no serviceable parts except for the metal gaskets, rubber O-ring seals and the service port valve cores. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid and suction line assembly is disconnected. The lower A/C suction line and the A/C liquid and suction line assembly cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7285 Hose/Line HVAC: Description and Operation A/C Underbody Lines - Description DESCRIPTION Models equipped with the rear heating-A/C system use metal lines attached to the vehicle underbody to carry refrigerant and engine coolant to and from the rear A/C evaporator and heater core. The underbody A/C lines (1) are connected to the front A/C suction and liquid lines and to the rear A/C expansion valve extension tubes using nut type fittings (4) and O-ring seals. The underbody heater lines (2) are connected to the front heater hoses and the rear heater core using spring type clamps (3). The underbody lines are retained to the vehicle by seven plastic mounting brackets (5). NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. The underbody lines have no serviceable parts except for the refrigerant line rubber O-ring seals and metal spring clamps. The O-ring seals used on the refrigerant line connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the underbody refrigerant lines are disconnected. The underbody lines cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7286 Hose/Line HVAC: Description and Operation A/C Underbody Extension Lines - Description DESCRIPTION Models equipped with the rear heating-A/C system use metal lines attached to the vehicle underbody to carry refrigerant and engine coolant to and from the rear A/C evaporator and heater core. The underbody A/C lines are connected to the front A/C suction and liquid lines by use of underbody A/C extension lines (2). The underbody A/C extension lines are connected to the front and underbody refrigerant lines with nut type fittings (1 and 3) and O-ring seals. NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. The underbody A/C extension lines have no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the refrigerant line connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the underbody refrigerant lines are disconnected. The underbody A/C extension lines cannot be repaired and must be replaced if leaking or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Remove the nut (5) that secures the A/C discharge line (1) to the condenser tapping block (2) located on the right side of the condenser. 4. Disconnect the A/C discharge line from the tapping block. NOTE: 2.7L shown. Other engines similar. 5. Remove the nut (3) that secures the A/C discharge line (1) to the A/C compressor (2). 6. Disconnect the A/C discharge line from the A/C compressor and remove the discharge line from the engine compartment. 7. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened discharge line fittings and the compressor and condenser ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7289 Hose/Line HVAC: Service and Repair A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: 2.7L shown. Other engines similar. 1. Remove the tape or plugs from the opened discharge line fittings and the compressor and condenser ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C discharge line (1) into the engine compartment and connect it to the A/C compressor (2). 4. Install the nut (3) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 5. Connect the A/C discharge line (1) to the condenser tapping block (2). 6. Install the nut (5) that secures the A/C discharge line to the tapping block. Tighten the nut to 20 Nm (15 ft. lbs.). 7. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7290 CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 8. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 10. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7291 Hose/Line HVAC: Service and Repair A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: The rear A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 6. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal and gasket. 7. Disconnect the lower portion of the A/C suction line from the A/C liquid and suction line assembly See: A/C Suction Line - Removal. 8. Remove the bolt (3) that secures the rear section of the A/C suction line (2) to the right front frame rail. 9. Lower the vehicle. 10. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7292 heat shield retaining nuts is not required. 11. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and power steering fluid is not required. 12. Remove the engine coolant reservoir from the right side of the engine compartment and position it out of the way See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle Removal. 13. Remove the power steering fluid reservoir from the right front strut tower and position it out of the way See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 14. If equipped with ABS, remove the ABS control module and pump assembly and position the brake lines out of the way as necessary See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) Installation. 15. Disconnect the wire harness connector from the A/C pressure transducer (7) located on the A/C liquid line and remove the transducer if required See: Refrigerant Pressure Sensor / Switch/Service and Repair/Front A/C Pressure Transducer Removal. 16. If equipped with rear A/C, disconnect the rear A/C extension lines from the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Removal. 17. Remove the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. 18. Remove the nut (5) that secures the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). 19. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and discard the O-ring seals. 20. Remove the A/C liquid and suction line assembly from the engine compartment. 21. Install plugs in, or tape over all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7293 Hose/Line HVAC: Service and Repair A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. 1. Remove the tape or plugs from all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. 2. Lubricate new rubber O-rings with clean refrigerant oil and install them and new gaskets onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C liquid and suction line assembly (1) into the engine compartment. 4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 6. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 7. If equipped with rear A/C, connect the rear A/C extension lines to the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Installation. 8. If removed, lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the fitting for the A/C pressure transducer (7) located on the A/C liquid line and install the pressure transducer. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7294 9. Connect the wire harness connector to the A/C pressure transducer. 10. If equipped with ABS, install the ABS control module and pump assembly See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. 11. Install the power steering fluid reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. 12. Install the engine coolant reservoir See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation. 13. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 14. Raise and support the vehicle. 15. Install the bolt (3) that secures the upper portion of the A/C suction line (2) to the right front frame rail. Tighten the bolt securely 16. Install the lower portion of the A/C suction line to the upper suction line See: A/C Suction Line - Installation. 17. Connect the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 18. Install the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). Tighten the nut to 20 Nm (15 ft. lbs.). 19. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If equipped with ABS, bleed the brake system See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7295 23. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 24. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 25. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7296 Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Remove the nut (5) that secures the A/C discharge line (1) to the condenser tapping block (2) located on the right side of the condenser. 4. Disconnect the A/C discharge line from the tapping block. NOTE: 2.7L shown. Other engines similar. 5. Remove the nut (3) that secures the A/C discharge line (1) to the A/C compressor (2). 6. Disconnect the A/C discharge line from the A/C compressor and remove the discharge line from the engine compartment. 7. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened discharge line fittings and the compressor and condenser ports. A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7297 . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: 2.7L shown. Other engines similar. 1. Remove the tape or plugs from the opened discharge line fittings and the compressor and condenser ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C discharge line (1) into the engine compartment and connect it to the A/C compressor (2). 4. Install the nut (3) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 5. Connect the A/C discharge line (1) to the condenser tapping block (2). 6. Install the nut (5) that secures the A/C discharge line to the tapping block. Tighten the nut to 20 Nm (15 ft. lbs.). 7. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 8. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 10. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7298 A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: The rear A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 6. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal and gasket. 7. Disconnect the lower portion of the A/C suction line from the A/C liquid and suction line assembly See: A/C Suction Line - Removal. 8. Remove the bolt (3) that secures the rear section of the A/C suction line (2) to the right front frame rail. 9. Lower the vehicle. 10. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7299 11. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and power steering fluid is not required. 12. Remove the engine coolant reservoir from the right side of the engine compartment and position it out of the way See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle Removal. 13. Remove the power steering fluid reservoir from the right front strut tower and position it out of the way See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 14. If equipped with ABS, remove the ABS control module and pump assembly and position the brake lines out of the way as necessary See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) Installation. 15. Disconnect the wire harness connector from the A/C pressure transducer (7) located on the A/C liquid line and remove the transducer if required See: Refrigerant Pressure Sensor / Switch/Service and Repair/Front A/C Pressure Transducer Removal. 16. If equipped with rear A/C, disconnect the rear A/C extension lines from the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Removal. 17. Remove the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. 18. Remove the nut (5) that secures the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). 19. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and discard the O-ring seals. 20. Remove the A/C liquid and suction line assembly from the engine compartment. 21. Install plugs in, or tape over all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7300 NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. 1. Remove the tape or plugs from all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. 2. Lubricate new rubber O-rings with clean refrigerant oil and install them and new gaskets onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C liquid and suction line assembly (1) into the engine compartment. 4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 6. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 7. If equipped with rear A/C, connect the rear A/C extension lines to the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Installation. 8. If removed, lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the fitting for the A/C pressure transducer (7) located on the A/C liquid line and install the pressure transducer. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 9. Connect the wire harness connector to the A/C pressure transducer. 10. If equipped with ABS, install the ABS control module and pump assembly See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. 11. Install the power steering fluid reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. 12. Install the engine coolant reservoir See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7301 13. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 14. Raise and support the vehicle. 15. Install the bolt (3) that secures the upper portion of the A/C suction line (2) to the right front frame rail. Tighten the bolt securely 16. Install the lower portion of the A/C suction line to the upper suction line See: A/C Suction Line - Installation. 17. Connect the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 18. Install the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). Tighten the nut to 20 Nm (15 ft. lbs.). 19. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If equipped with ABS, bleed the brake system See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 23. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 24. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 25. Charge the A/C system See: Service and Repair/Refrigerant System Charge. A/C Suction Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7302 Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: The A/C suction line is serviced in two sections. NOTE: LHD model shown in illustrations. Upper A/C Suction Line NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the rear A/C liquid line. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 6. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal and gasket. 7. Disconnect the lower portion of the A/C suction line from the A/C liquid and suction line assembly See: A/C Suction Line - Removal. 8. Remove the bolt (3) that secures the rear section of the A/C suction line (2) to the right front frame rail. 9. Lower the vehicle. 10. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required. 11. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7303 remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and power steering fluid is not required. 12. Remove the engine coolant reservoir from the right side of the engine compartment and position it out of the way See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle Removal. 13. Remove the power steering fluid reservoir from the right front strut tower and position it out of the way See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal. 14. If equipped with ABS, remove the ABS control module and pump assembly and position the brake lines out of the way as necessary See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) Installation. 15. Disconnect the wire harness connector from the A/C pressure transducer (7) located on the A/C liquid line and remove the transducer if required See: Refrigerant Pressure Sensor / Switch/Service and Repair/Front A/C Pressure Transducer Removal. 16. If equipped with rear A/C, disconnect the rear A/C extension lines from the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Removal. 17. Remove the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. 18. Remove the nut (5) that secures the A/C liquid and suction line assembly (1) to the A/C expansion valve (4). 19. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and discard the O-ring seals. 20. Remove the A/C liquid and suction line assembly from the engine compartment. 21. Install plugs in, or tape over all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. Lower A/C Suction Line Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7304 NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (2) that secures the lower A/C suction line (3) to the upper A/C suction line (1). 6. Disconnect the lower A/C suction line to the upper A/C suction line and remove and discard the O-ring seal and gasket. NOTE: 2.7L shown. Other engines similar. 7. Remove the nut (2) that secures the lower A/C suction line (1) to the A/C compressor (3). 8. Disconnect the lower A/C suction line from the A/C compressor and remove the lower line from the engine compartment. 9. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over all the opened suction line fittings and the compressor port. A/C Suction Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7305 NOTE: LHD model shown in illustrations. Upper A/C Suction Line 1. Remove the tape or plugs from all of the opened refrigerant line fittings and the expansion valve and receiver/drier ports. 2. Lubricate new rubber O-rings with clean refrigerant oil and install them and new gaskets onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the A/C liquid and suction line assembly (1) into the engine compartment. 4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (4). CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 6. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely. 7. If equipped with rear A/C, connect the rear A/C extension lines to the fittings (3) located on the A/C liquid and suction line assembly See: A/C Underbody Lines - Installation. 8. If removed, lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the fitting for the A/C pressure transducer (7) located on the A/C liquid line and install the pressure transducer. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 9. Connect the wire harness connector to the A/C pressure transducer. 10. If equipped with ABS, install the ABS control module and pump assembly See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. 11. Install the power steering fluid reservoir See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation. 12. Install the engine coolant reservoir See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7306 13. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 14. Raise and support the vehicle. 15. Install the bolt (3) that secures the upper portion of the A/C suction line (2) to the right front frame rail. Tighten the bolt securely 16. Connect the lower portion of the A/C suction line to the A/C liquid and suction line assembly See: A/C Suction Line Installation. 17. Connect the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). 18. Install the nut (5) that secures the rear section of the A/C liquid line (1) to the A/C receiver/drier (4). Tighten the nut to 20 Nm (15 ft. lbs.). 19. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If equipped with ABS, bleed the brake system See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Removal and Replacement/Integrated Control Unit (ICU) - Installation. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 23. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 24. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 25. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Lower A/C Suction Line Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7307 NOTE: 2.7L shown. Other engines similar. 1. Position the lower A/C suction line (1) into the engine compartment. 2. Remove the tape or plugs from the suction line fittings and the compressor port. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the lower A/C suction line to the A/C compressor (3). 5. Install the nut (2) that secures the lower A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). NOTE: Illustration shown with front fascia and headlamp removed for clarity. 6. Connect the lower portion of the A/C suction line (3) to the upper suction line (1) 7. Install the nut (2) that secures the lower portion of the A/C suction line to the upper suction line. Tighten the nut to 20 Nm (15 ft. lbs.). 8. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 9. Lower the vehicle. 10. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 11. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 12. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 13. Charge the A/C system See: Service and Repair/Refrigerant System Charge. A/C Underbody Lines - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7308 WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: To prevent any contaminates from entering the rear heating-A/C system, make sure that the area around the underbody line connections is clean of any dirt or foreign residue prior to disconnecting the lines. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Raise and support the vehicle. 5. Remove the rear section of the exhaust system See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe Removal. 6. Remove the exhaust heat shields as necessary to gain access to the underbody lines See: Engine, Cooling and Exhaust/Exhaust System/Heat Shield/Description and Operation/Description. NOTE: Replacement of the front heater hoses will be required if the hose ends are cut for removal. 7. Release the spring type hose clamps (2) and disconnect the front heater hoses (1) from the underbody heater lines (4). 8. Loosen the fitting nuts (6) that secure the underbody refrigerant lines (5) to the front A/C liquid and suction lines (7). 9. Disconnect the front A/C liquid and suction lines from the underbody refrigerant lines and remove and discard the O-ring seals. 10. Disengage the front A/C liquid and suction lines from the front underbody refrigerant line bracket (3). 11. Remove the two nuts (3) and one screw (1) that secure the underbody line shield (2) to the vehicle underbody and remove the shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7309 CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater tubes when disconnecting the connections. Excessive force may damage or deform the tubes and or lines, causing an engine coolant leak. NOTE: Replacement of the rubber heater hose ends will be required if the rubber hoses are cut for removal. 12. Release the spring type hose clamps (4) and disconnect the underbody heater lines (5) from the rear heater core tubes located behind the right rear wheel housing. 13. Lower the underbody heater lines and drain any residual coolant from the lines into a suitable container. 14. Loosen the fitting nuts (1) that secure the underbody refrigerant lines (7) to the underbody refrigerant extension lines and sealing plate (2 and 6). 15. Disconnect the underbody refrigerant lines from underbody refrigerant extension lines and remove and discard the O-ring seals. 16. Remove the nut (3) that secures the underbody refrigerant extension lines and sealing plate to the rear A/C expansion valve. 17. Disconnect the extension lines and sealing plate from the rear A/C expansion valve and remove and discard the O-ring seals. 18. Disconnect the rear ABS wire harness lead and bracket (4) from the right side of the body (3) to gain clearance to partially lower the right side of the rear cradle. NOTE: It is not necessary to disconnect the brake line to remove it from the brackets. 19. Remove the two bolts (6) that secure the right rear brake line (1) to the two brackets (2 and 5) and remove the brake line from the brackets to gain clearance to partially lower the right side of the rear cradle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7310 NOTE: Illustration shown with rear body cradle removed for clarity. 20. Remove the lower right rear shock retaining bolt See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over Removal. WARNING: Be sure to properly support the rear cradle before removing the right side retaining bolts. Failure to follow this warning may result in serious or fatal injury. 21. Support the right side of the rear cradle with a suitable jack stand and remove the bolts that secure the right side of the cradle to the body See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal. CAUTION: Use care not to damage the ABS wire lead or the brake line when lowering the rear cradle for clearance. 22. Carefully lower the jack stand until the right side of the rear cradle (supported by the stand) is approximately 76-101 mm (3-4 in.) below the body. This will allow access to remove the underbody line assembly. 23. Remove the nut (5) that secures the underbody line bracket (4) to the stud located near the center of the underbody (6). 24. Disengage the remainder of the underbody line brackets (1, 2, and 7) from the studs located underneath the vehicle. 25. Rotate and tilt the underbody lines (3) as necessary and remove the lines from the vehicle. 26. Install plugs in, or tape over all the opened refrigerant line fittings and the rear expansion valve ports. 27. If required, place the extension lines and sealing plate (1) on a workbench, remove the nylon retaining clip (4) that secures the suction extension line (3) to the sealing plate and remove the suction line from the sealing plate. A/C Underbody Lines - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7311 INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. 1. If removed, install the suction extension line (3) into the sealing plate (1) and install the nylon retaining clip (4). NOTE: Illustration shown with rear body cradle removed for clarity. 2. Position the underbody lines (3) and engage the underbody line brackets (1, 2, and 7) to the mounting studs located on the underbody (6). Rotate and tilt the underbody lines as necessary. Make sure the brackets are fully engaged to the studs. 3. Position the underbody line bracket (4) onto the mounting stud located near the center of the underbody and install the retaining nut (5). Tighten the nut securely. CAUTION: Use care not to damage the ABS wire lead or the brake line when repositioning the rear cradle. 4. Carefully raise the jack stand until the right side of the rear cradle is positioned to the body. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7312 WARNING: Be sure to properly support the rear cradle when installing the right side retaining bolts. Failure to follow this warning may result in serious or fatal injury. 5. Install the bolts that secure the right side of the cradle to the body and remove the jack stand See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation. 6. Install the lower right rear shock retaining bolt See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over Installation. 7. Connect the rear ABS wire harness lead and bracket (4) to the right side of the body (3). 8. Position the right rear brake line (1) onto the two brackets (2 and 5) and install the two retaining bolts (6). Tighten the bolts securely. CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater tubes fittings when connecting the connections. Excessive force may damage or deform the tubes and or lines, causing an engine coolant leak. NOTE: Replacement of the rubber heater hose ends will be required if the rubber hoses were cut for removal. 9. Remove the tape or plugs from all the opened refrigerant line fittings and the rear expansion valve ports. 10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant extension line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 11. Connect the underbody refrigerant extension lines and sealing plate (2 and 6) to the rear A/C expansion valve. 12. Loosely install the nut (3) that secures the extension lines and sealing plate to the rear A/C expansion valve. 13. Connect the underbody refrigerant lines (7) to the underbody refrigerant extension lines and tighten the fitting nuts (1) to 23 Nm (17 ft. lbs.). 14. Tighten the nut that secures the extension lines and sealing plate to the rear A/C expansion valve to 11 Nm (97 in. lbs.). 15. Connect the underbody heater lines (5) to the rear heater core tubes located behind the right rear wheel housing and engage the spring type hose clamps (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7313 16. Position the underbody line shield (2) to the vehicle underbody and install the two nuts (3) and one screw (1). Tighten the fasteners securely. 17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 18. Connect the front A/C liquid and suction lines (7) to the underbody refrigerant lines (5). Tighten the fitting nuts (6) to 23 Nm (17 ft. lbs.). 19. Position the front A/C liquid and suction lines into the front underbody refrigerant line bracket (3) and engage the bracket retainer. NOTE: Replacement of the front heater hoses will be required if the hose ends were cut for removal. 20. Connect the front heater hoses (1) to the underbody heater lines (4) and engage the spring type hose clamps (2). 21. Install the exhaust heat shields as necessary. 22. Install the rear section of the exhaust system See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe Installation. 23. Lower the vehicle. 24. Reconnect the negative battery cable. 25. Fill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 26. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 27. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 28. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. A/C Underbody Extension Lines - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: To prevent any contaminates from entering the rear heating-A/C system, make sure that the area around the underbody line Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7314 connections is clean of any dirt or foreign residue prior to disconnecting the lines. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Disengage the underbody A/C extension lines (4) from the front underbody refrigerant line bracket (1). 5. Loosen the fitting nuts (3) that secure the underbody A/C extension lines to the underbody A/C liquid and suction lines (2). 6. Disconnect the underbody A/C extension lines from the underbody A/C liquid and suction lines and remove and discard the O-ring seals. 7. Install plugs in, or tape over the opened refrigerant line fittings. 8. Lower the vehicle. 9. Loosen the fitting nuts (3) that secure the underbody A/C extension lines (2) to the front A/C liquid and suction lines (1). 10. Disconnect the underbody A/C extension lines from the front A/C liquid and suction lines and remove and discard the O-ring seals. 11. Rotate and tilt the underbody A/C extension lines as necessary and remove the lines from the vehicle. 12. Install plugs in, or tape over the opened refrigerant line fittings. A/C Underbody Extension Lines - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 7315 1. Remove the tape or plugs from the opened refrigerant extension line fittings. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Position the underbody A/C extension lines (2) into the engine compartment. Rotate and tilt the underbody A/C extension lines as necessary. 4. Connect the underbody A/C extension lines to the front A/C liquid and suction lines (1). Tighten the fitting nuts (3) to 23 Nm (17 ft. lbs.). 5. Raise and support the vehicle. 6. Remove the tape or plugs from the opened underbody refrigerant line fittings. 7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the underbody A/C extension lines (4) to the underbody A/C liquid and suction lines (2). Tighten the fitting nuts (3) to 23 Nm (17 ft. lbs.). 9. Position the underbody A/C extension lines into the front underbody refrigerant line bracket (1) and engage the bracket retainer. 10. Lower the vehicle. 11. Reconnect the negative battery cable. 12. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 13. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 14. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation > Front Housing Assembly HVAC: Description and Operation Front DESCRIPTION NOTE: LHD model shown. All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of three separate housings: - HVAC housing - The HVAC housing (1) is mounted to the dash panel behind the instrument panel and contains the A/C evaporator. The HVAC housing consists of an upper and a lower housing that are attached together and has mounting provisions for the air inlet housing, blower motor and the air distribution housing. - Air distribution housing - The air distribution housing (2) is mounted to the rear of the HVAC housing and contains the heater core, blend-air and mode-air doors and door linkage. - Air inlet housing - The air inlet housing (3) is mounted to the passenger side end of the HVAC housing and contains the recirculation-air door and actuator. The heating-A/C system is a blend-air type system. The blend-air door controls the amount of conditioned air that is allowed to flow through, or around the heater core. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the electric blend door actuator, which moves the blend-air door. This allows an almost immediate control of the output air temperature of the system. The electric mode door actuator operates the mode-air door. The electric recirculation door actuator operates the recirculation-air door which closes off the fresh air intake into the HVAC housing and recirculates the air already inside the vehicle. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor resistor or power module (depending on application), which is located on the bottom of the HVAC housing. The actuators, resistor or power module and the blower motor are connected to the vehicle electrical system by the instrument panel wire harness. The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation > Front > Page 7320 Housing Assembly HVAC: Description and Operation Rear DESCRIPTION Models with the rear heating-A/C system use a rear heater-A/C housing (1) that combines A/C and heating capabilities into a single unit mounted within the rear passenger compartment. The rear heating-A/C system is a blend-air type system. A blend-air door controls the amount of conditioned air that is allowed to flow through, or around, the heater core (9). The rear A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C expansion valve (7) and A/C evaporator (6) to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator (3), which moves the blend-air door. This allows an almost immediate control of the output air temperature of the rear system. The mode control operates the mode door actuator (2) that positions the mode-air door to direct the flow of the conditioned air out the upper or lower air outlets, depending on the position selected. Both electric door actuators are connected to the vehicle electrical system by the rear heater-A/C wire harness (8). The rear blower motor (4) controls the velocity of air flowing through the rear heater-A/C housing by spinning the blower wheel within the rear housing at the selected speed by use of the rear blower motor resistor or power module (5) (depending on manual or automatic control). The rear heater-A/C housing must be removed from the vehicle for service of the mode door actuator and blend door actuator and it must be disassembled for service of the A/C evaporator and the heater core. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Front Air Distribution Housing Removal HOUSING-AIR DISTRIBUTION WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. NOTE: LHD model shown in illustrations. 1. Remove the HVAC housing assembly and place it on a workbench . 2. Remove the floor distribution ducts from the HVAC housing assembly See: Air Duct/Service and Repair/Floor Distribution Duct - Removal. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (5). 4. Remove the screw (6) that secures the flange to the HVAC housing and remove the flange. 5. On RHD models, remove the air distribution housing (3) from the HVAC housing 6. Carefully pull the heater core (4) out of the air distribution housing. 7. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7323 8. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing. 9. Remove the air distribution housing from the rear of the HVAC housing. 10. If required, disassemble the air distribution housing See: Overhaul/Disassembly. Front Air Distribution Housing Installation HOUSING-AIR DISTRIBUTION NOTE: LHD model shown in illustrations. 1. Position the air distribution housing (2) onto the rear of the HVAC housing (4). 2. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the HVAC housing. 3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 4. Carefully install the heater core (4) into the side of the air distribution housing (3). 5. On RHD models, install the air distribution housing onto the HVAC housing (5) . 6. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 7. Install the screw (6) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 8. Install the foam seal (1) onto the flange. 9. Install all of the floor distribution ducts onto the air distribution housing See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 10. Install the HVAC housing assembly . Front Air Inlet Housing Removal HOUSING-AIR INLET Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7324 WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: LHD model shown. 1. Remove the HVAC housing assembly and place it on a workbench . 2. If equipped, remove the particulate air filter See: Cabin Air Filter/Service and Repair/Removal and Replacement/Particulate Air Filter - Removal. 3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3). 4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC housing and remove the inlet housing from the HVAC housing. 5. If required, disassemble the air inlet housing See: Overhaul/Disassembly. Front Air Inlet Housing Installation HOUSING-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic retaining tabs (4). Make sure the retaining tabs are fully engaged. 2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. If equipped, install the particulate air filter See: Cabin Air Filter/Service and Repair/Removal and Replacement/Particulate Air Filter - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7325 4. Install the HVAC housing assembly . Front Air Inlet Screen Removal SCREEN-AIR INLET NOTE: LHD model shown. 1. Remove the cowl grille screen See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair. 2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl panel (3) and remove the screen. Front Air Inlet Screen Installation SCREEN-AIR INLET NOTE: LHD model shown. 1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-in retainers (1) that secure the screen to the panel. 2. Install the cowl grille screen See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair. Front HVAC Housing Removal HOUSING-HVAC WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7326 WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors. NOTE: LHD model shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Partially drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. If equipped with heat shield (3), remove the top nut (2) that secures the heat shield to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal, if equipped. Complete removal of the two bottom heat shield retaining nuts is not required. 5. If equipped, reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. 6. Remove the nut (1) that secures the A/C liquid and suction line assembly (2) to the A/C expansion valve (3). 7. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 8. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 9. Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7327 NOTE: Make sure to remove the five bolts that secure the HVAC housing to the instrument panel support prior to removing the instrument panel from the vehicle. 10. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 11. Remove the rear floor ducts See: Air Duct/Service and Repair/Floor Distribution Duct Removal. 12. Remove the condensation drain tube. 13. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3). NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores. 14. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment. 15. If required, remove the HVAC housing air inlet duct (2) from the passenger compartment side of the dash panel (1). Front HVAC Housing Installation HOUSING-HVAC NOTE: LHD model shown in illustrations. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7328 1. If removed, install the HVAC housing air inlet duct (2) onto the passenger compartment side of the dash panel (1). Make sure the foam seal is not missing or damaged and that the retaining tabs are fully engage to the dash panel. 2. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud. 3. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel. Tighten the nut to 4.5 Nm (40 in. lbs.). 4. Install the condensation drain tube. 5. Install the rear floor ducts See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. 6. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. 7. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core tubes. 8. Remove the tape or plugs from the refrigerant line fittings and the expansion valve ports. 9. Lubricate the rubber O-ring seals with clean refrigerant oil and install them onto the liquid and suction line fittings. Use only the specified O-ring Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7329 seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 10. Connect the A/C liquid and suction line assembly (2) to the A/C expansion valve (3). 11. Install the nut (1) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the nut to 20 Nm (15 ft. lbs.). 12. If equipped, position the heat shield (3) onto the studs (1) located on the dash panel in the engine compartment and install the retaining nuts (2). Tighten the nuts to 1 Nm (10 in. lbs.). 13. Reconnect the negative battery cable. 14. If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 15. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 16. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. 17. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics. Rear HVAC Housing Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: The rear heater-A/C housing must be removed from the vehicle for service of the mode door actuator and blend door actuator and it must be disassembled for service of the A/C evaporator and the heater core. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7330 3. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Raise and support the vehicle. CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater tubes when disconnecting the connections. Excessive force may damage or deform the tubes and or lines, causing an engine coolant leak. NOTE: Replacement of the rubber heater hose ends will be required if the rubber hoses are cut for removal. 5. Release the spring type hose clamps (4) and disconnect the underbody heater lines (5) from the rear heater core tubes located behind the right rear wheel housing. 6. Lower the underbody heater lines and drain any residual coolant from the lines into a suitable container. 7. Loosen the fitting nuts (1) that secure the underbody refrigerant lines (7) to the underbody refrigerant extension lines and sealing plate (2 and 6). 8. Disconnect the underbody refrigerant lines from underbody refrigerant extension lines and remove and discard the O-ring seals. 9. Remove the nut (3) that secures the underbody refrigerant extension lines and sealing plate to the rear A/C expansion valve. 10. Disconnect the extension lines and sealing plate from the rear A/C expansion valve and remove and discard the O-ring seals. 11. Install plugs in, or tape over the opened underbody refrigerant line fittings and rear expansion valve ports. 12. Lower the vehicle. 13. Remove the right D-pillar trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 14. Remove right quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 15. Remove the two bolts (2) that secure the upper seat belt bracket (1) to the right D-pillar (3) and remove the bracket. 16. Remove the two bolts (4) that secure the right seat belt retractor (5) to the right D-pillar and remove the retractor. 17. Remove the two retainers (4 and 5) that secure the rear ceiling distribution duct (3) to the right D-pillar (2). 18. Lift the rear ceiling distribution duct upward and disengage it from the rear heater-A/C housing (1). CAUTION: Use care when removing the rear ceiling distribution duct from the heater-A/C housing to prevent damage to the molded plastic support brace located on the top of the housing outlet. Failure to follow this caution could result in part of, or all of the support Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7331 brace falling into the rear housing, which may interfere with rear mode door operation. 19. Pull the bottom end of the rear ceiling distribution duct away from the rear heater-A/C housing and remove the duct. 20. Remove the push-pin retainer (2) that secures the rear floor distribution duct (1) to the right inner quarter panel (3). 21. Disengage the rear floor distribution duct from the stud (5) located on the right inner quarter panel. 22. Disengage the rear floor distribution duct from the rear heater-A/C housing (4) and remove the duct. NOTE: MTC rear heater-A/C system shown. ATC system similar. 23. Disconnect the body wire harness connectors (8 and 9) from the rear blower motor (2) and the rear blower motor resistor or power module (3) (depending on control system). 24. Disconnect the body wire harness connector (6) from the rear heater-A/C wire harness connector (5). 25. Remove the two bolts (4 and 10) that secure the rear heater-A/C housing (1) to the right inner quarter panel (7) and remove the housing. Rear HVAC Housing Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7332 NOTE: MTC rear heater-A/C system shown. ATC system similar. 1. Position the rear heater-A/C housing (1) into the vehicle and align the guide pins on the housing to the holes in the right inner quarter panel (7). 2. Install the two bolts (4 and 10) that secure the rear heater-A/C housing to the right inner quarter panel. Tighten the bolts to 3 Nm (27 in. lbs.). 3. Connect the body wire harness connector (6) to the rear heater-A/C wire harness connector (5). 4. Connect the body wire harness connectors (8 and 9) to the rear blower motor (2) and the rear blower motor resistor or power module (3) (depending on control system). 5. Install the rear floor distribution duct (1) onto rear heater-A/C housing (4). Make sure the duct is fully engaged to the housing. 6. Engage the rear floor distribution duct to the stud (5) located on the right inner quarter panel (3). 7. Install the push-pin retainer (2) that secures the rear floor distribution duct to the right inner quarter panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7333 8. Position the rear ceiling distribution duct (3) to the right D-pillar (2). CAUTION: Use care when installing the rear ceiling distribution duct onto the heater-A/C housing to prevent damage to the molded plastic support brace located on the top of the housing outlet. Failure to follow this caution could result in part of, or all of the support brace falling into the rear housing, which may interfere with rear mode door operation. 9. Install the rear ceiling distribution duct onto the top of the rear heater-A/C housing (1). Make sure the duct is fully engaged to the housing. 10. Install the two retainers (4 and 5) that secure the rear ceiling distribution duct to the right D-pillar. 11. Position the upper seat belt bracket (2) onto the D-pillar (3) and install the two retaining bolts (1). Tighten the bolts to 52 Nm (38.5 ft. lbs.). 12. Install the right seat belt retractor (5) and retaining bolts (4) onto the D-pillar. Tighten the bolts to 52 Nm (38.5 ft. lbs.). 13. Install the right quarter trim panel, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 14. Install the right D-pillar trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7334 15. Raise and support the vehicle. CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater tubes fittings when connecting the connections. Excessive force may damage or deform the tubes and or lines, causing an engine coolant leak. NOTE: Replacement of the rubber heater hose ends will be required if the rubber hoses were cut for removal. 16. Remove the tape or plugs from all the opened refrigerant line fittings and the rear expansion valve ports. 17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant extension line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 18. Connect the underbody refrigerant extension lines and sealing plate (2 and 6) to the rear A/C expansion valve. 19. Loosely install the nut (3) that secures the extension lines and sealing plate to the rear A/C expansion valve. 20. Connect the underbody refrigerant lines (7) to the underbody refrigerant extension lines and tighten the fitting nuts (1) to 23 Nm (17 ft. lbs.). 21. Tighten the nut that secures the extension lines and sealing plate to the rear A/C expansion valve to 11 Nm (97 in. lbs.). 22. Connect the underbody heater lines (5) to the rear heater core tubes located behind the right rear wheel housing and engage the spring type hose clamps (4). 23. Lower the vehicle. 24. Reconnect the negative battery cable. 25. If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 26. Fill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 27. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. 28. Calibrate the A/C-heater control See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7335 Housing Assembly HVAC: Overhaul Front Air Distribution Housing HOUSING-AIR DISTRIBUTION NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. NOTE: LHD model with A/C shown in illustrations. Heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench . 2. Remove the air distribution housing (2) from the HVAC housing (1) . 3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing . 4. Remove the heater core from the air distribution housing See: Heater Core/Service and Repair/Front Heater Core - Removal. 5. Remove the screws (1) that secure the blend door actuator (2) to the left side of the air distribution housing (3) and remove the actuator. 6. If equipped with dual zone system, remove the screws that secure the other blend door actuator to the right side of the air distribution housing and remove the actuator See: Air Door/Air Door Actuator / Motor/Service and Repair/Blend Door Actuator - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7336 7. Remove the blend door lever (1) from the left side of the air distribution housing (2). NOTE: To remove the blend door pivot lever, disengage the retaining tab on the lever and pull the lever straight off the pivot shaft. 8. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4). NOTE: It is not necessary to remove the mode door actuator from the bracket when servicing the air distribution housing. 9. Remove the three screws (1) that secure the mode door actuator (2) and bracket (3) to the right side of the air distribution housing (4) and remove the actuator and bracket as an assembly. 10. Remove the mode door cam (1) from the right side of the air distribution housing (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7337 NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced. 11. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced. 12. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. 13. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced. NOTE: If equipped with dual zone heating/A/C system, there are two blend-air doors that mate together at the centerline of the housing. 14. Disengage the air doors (1, 2, 3 and 4) from the door levers and remove the air doors from the air distribution housing (5). NOTE: To remove the door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7338 15. If required, remove the door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5). Front Air Inlet Housing HOUSING-AIR INLET NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: LHD model shown in illustrations. 1. Remove the HVAC housing assembly and place it on a workbench . 2. Remove the air inlet housing (3) from the HVAC housing (1). 3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the air inlet housing (3) and remove the actuator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7339 4. To remove the recirculation door pivot shaft adapter from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing, then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft. NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced. NOTE: If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be replaced. 5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced. Front HVAC Housing HOUSING-HVAC NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. NOTE: LHD model shown in illustrations. 1. Remove the HVAC housing assembly and place it on a workbench . 2. Remove the air distribution housing (2) from the HVAC housing (1) . 3. Remove the air inlet housing (3) from the HVAC housing . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7340 NOTE: Manual temperature system shown. Automatic system similar. 4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to the bottom of the HVAC housing (4) and remove the blower motor and wire lead bracket. 5. Remove the two screws (5) that secure the blower motor resistor or power module (6) to the bottom of the HVAC housing and remove the resistor or power module. 6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor. NOTE: If the foam seal or plastic flange is deformed or damaged, it must be replaced. 7. Remove the two bolts that secure the A/C expansion valve (6 to the A/C evaporator and remove the valve See: Expansion Valve/Service and Repair/A/C Expansion Valve - Removal. 8. Remove and discard the O-ring seals and install plugs in, or tape over the opened expansion valve and evaporator tube ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7341 9. Remove the foam seal and plastic flange (2) from the front of the two halves of the HVAC housing (4). Carefully release the four retaining tabs located at the back of the flange and pull the flange off of the evaporator tubes. If the seal or flange is deformed or damaged, it must be replaced. 10. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. 11. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing. 12. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). Rear HVAC Housing DISASSEMBLY NOTE: The rear heater-A/C housing must be removed from the vehicle for service of the mode door actuator and blend door actuator and it must be disassembled for service of the A/C evaporator and the heater core. The blend-air door and mode-air door are only serviced with the respective housing. 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing and place it on a workbench See: Removal and Replacement/Rear HVAC Housing Removal. 3. Remove the rear blower motor resistor or power module (depending on application) or See: Control Module HVAC/Service and Repair/Rear Blower Motor Power Module - Removal. 4. Remove the rear blower motor . 5. Remove the foam seal (2) from the flange (1) located at the bottom of the rear heater-A/C housing (3). If the foam seal is deformed or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7342 6. Remove the three screws (2) that secure the flange (1) to the bottom of the rear heater-A/C housing (3) and remove the flange. 7. Remove the two screws (1) that secure the rear expansion valve (3) to the tapping plate located on the end of the rear evaporator tubes (2) and remove the valve. 8. Remove and discard the O-ring seals and install plugs in, or tape over the opened evaporator tubes and expansion valve ports. 9. Remove the wire harness connector (7) from the lower rear heater-A/C housing (6). 10. Open the evaporator tube retaining bracket (3) located on the outboard side of the lower housing. 11. Remove the metal retaining clip (2) that secures the lower housing to the rear heater-A/C housing (4). 12. Remove the five screws (1 and 5) that secure the lower housing the rear heater-A/C housing and carefully remove the lower housing. Rotate and tilt the lower housing as necessary for removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7343 13. Remove the screw (1) that secures the rear evaporator cover (3) to the outboard side of the rear heater-A/C housing (2) and remove the cover of the housing. 14. Carefully pull the rear A/C evaporator (4) out the bottom of the rear heater-A/C housing (3). Guide the evaporator tubes (2) past the heater core tubes (1). If the foam seals on the A/C evaporator are deformed or damaged, they must be replaced. 15. Disconnect the wire harness connector (3) from the rear blend door actuator (2) located on the outboard side of the rear heater-A/C housing (4). 16. Remove the two screws (1) that secure the rear blend door actuator to the rear heater-A/C housing and remove the actuator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7344 17. Disconnect the rear heater-A/C wire harness connector (1) from the rear mode door actuator (3) located on the outboard side of the rear heater-A/C distribution housing (2) and remove the wire harness from the rear heater-A/C housing (5). 18. Remove the three metal retaining clips (4) that secure the rear distribution housing to the rear heater-A/C housing. 19. Release the five plastic retaining tabs (4) that secure the rear distribution housing and rear heater-A/C housing together and separate the housings. 20. If required, remove the rear mode door actuator from the rear distribution housing See: Air Door/Air Door Actuator / Motor/Service and Repair/Mode Door Actuator - Removal. 21. Remove the screw (1) that secures the rear heater core tubes (3) to the outboard side of the rear heater-A/C housing (4). 22. Pull the rear heater core (5) out of the top of the rear heater-A/C housing. If the foam seals on the heater core are deformed or damaged, they must be replaced. Front Air Distribution Housing HOUSING-AIR DISTRIBUTION NOTE: LHD model with A/C shown in illustrations. Heater-only models similar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7345 1. If removed, install the four door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5) Make sure the lever retaining tabs are fully engaged to the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced. NOTE: Properly position the air doors within the air distribution housing by first aligning the four door levers to the scribe lines located on the right outer side of the air distribution housing. Then, install the air doors onto the door levers with the UP mark on each air door facing toward the top of the housing. NOTE: If equipped with dual zone heating/A/C system, there are two blend-air doors that mate together at the centerline of the housing. 2. Align the four door levers to the scribe lines on the right outer side of the air distribution housing (5) and install the air door(s) (1, 2, 3 and 4) onto the door levers with the UP mark on each air door facing toward the top of the housing. 3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two halves of the housing together. Make sure the Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7346 three plastic retaining tabs (6) are fully engaged. 4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 Nm (20 in lbs.). Make sure the metal clip is fully engaged to the housing halves. NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced. 5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it must be replaced. NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam prior to installation of the cam. 6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam (1) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam. 7. Position the mode door actuator (2) and bracket (3) onto the right side of the HVAC air distribution housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door cam. 8. Install the screws (1) that secure the mode door actuator bracket to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7347 9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot shaft. NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of the blend door lever. 10. Install the blend door lever (1) onto the air distribution housing. Make sure the levers are correctly aligned to each other. 11. Position the blend door actuator (2) onto the left side of the air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend door lever. 12. Install the screws (1) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 13. If equipped with dual zone system, position the blend door actuator onto the right side of the air distribution housing and install the retaining screws. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend door. Tighten the screws to 2 Nm (17 in. lbs.). 14. If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient (PTC) heater unit into the air distribution housing (2) . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7348 15. Install the heater core into the air distribution housing See: Heater Core/Service and Repair/Front Heater Core - Installation. 16. Install the air distribution housing onto the HVAC housing (1) . 17. Install the HVAC housing assembly . Front Air Inlet Housing HOUSING-AIR INLET NOTE: LHD model shown in illustrations. 1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two ends of the air-door together and aligning the pivot shafts of the air-door to the pivot shaft holes in the air inlet housing. NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it straight into the end of the recirculation door pivot shaft. 2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the recirculation air-door. Make sure the adapter is fully engaged to the pivot shaft. 3. Install the recirculation door actuator (1) onto the right side of the air inlet housing (2). If necessary, rotate the actuator slightly to align the splines of the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7349 4. Install the air inlet housing (3) onto the HVAC housing (1) . 5. Install the HVAC housing assembly . Front HVAC Housing HOUSING-HVAC NOTE: LHD model shown in illustrations. NOTE: Make sure that the foam insulator is properly positioned around the A/C evaporator and in the HVAC housing. 1. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 2. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining tabs (1). Make sure the retaining tabs are fully engaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7350 3. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 Nm (10 in lbs.). Make sure the metal clips are fully engaged to the housing halves. NOTE: If the foam seal or plastic flange is deformed or damaged, it must be replaced. 4. Install the plastic flange and foam seal (2) over the evaporator tubes and onto the front of the HVAC housing. Make sure the four flange retaining tabs are fully engaged to the housing. 5. Remove the tape or plugs from the expansion valve and evaporator ports. 6. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 7. Install the A/C expansion valve (6) and the two retaining bolts. Tighten the bolts to 11 Nm (97 in. lbs.) See: Expansion Valve/Service and Repair/A/C Expansion Valve - Installation. 8. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing. NOTE: Manual temperature system shown. Automatic system similar. 9. Position the blower motor (3) into the bottom of the HVAC housing (4). 10. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 11. Position the blower motor resistor or power module (6) into the HVAC housing. 12. Install the two screws (5) that secure the resistor or power module to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7351 13. Install the air inlet housing (3) onto the HVAC housing (1) . 14. Install the air distribution housing (2) onto the HVAC housing . NOTE: If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 15. Install the HVAC housing assembly . Rear HVAC Housing ASSEMBLY CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level . NOTE: If only the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak. 1. Install the rear heater core (5) into the rear heater-A/C housing (4). Make sure that the foam seals are properly installed. 2. Install the screw (1) that secures the rear heater core tubes (3) to the outboard side of the rear heater-A/C housing. Tighten the screw to 1.2 Nm (10 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7352 3. If removed, install the rear mode door actuator (3) to the rear heater-A/C distribution housing (2) See: Air Door/Air Door Actuator / Motor/Service and Repair/Mode Door Actuator - Installation. 4. Position the rear heater-A/C distribution housing to the rear heater-A/C housing (5) and engage the five plastic retaining tabs (4). Make sure the retaining tabs are fully engaged. 5. Install the three metal retaining clips (6) that secure the rear distribution housing to the rear heater-A/C housing. 6. Position the rear heater-A/C wire harness (1) to the rear heater-A/C distribution housing and connect it to the rear mode door actuator (3). 7. Position the rear blend door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the rear blend-air door pivot shaft (2). 8. Install the two screws (1) that secure the rear blend door actuator (2) to the rear heater-A/C housing (4). Tighten the screws to 1.2 Nm (10 in. lbs.). 9. Connect the wire harness connector (3) to the rear blend door actuator. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7353 10. Install the rear A/C evaporator (4) into the rear heater-A/C housing (3). Guide the evaporator tubes (2) past the rear heater core tubes (1). Make sure that the foam seals are properly installed on the evaporator. 11. Install the evaporator cover (3) onto the outboard side of the rear heater-A/C housing (2) and install the retaining screw (1). Tighten the screw to 1.2 Nm (10 in. lbs.). 12. Install the lower rear heater-A/C housing (6) onto the rear heater-A/C housing (4). Rotate and tilt the lower housing as necessary for installation. 13. Install the five screws (1 and 5) that secure the lower housing to the rear heater-A/C housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 14. Install the metal retaining clip (2) that secures the lower housing to the rear heater-A/C housing. 15. Close the evaporator tube retaining bracket (3). Make sure the bracket retainers are fully engaged. 16. Install the wire harness connector (7) onto the lower rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7354 17. Remove the tape or plugs from the rear evaporator tubes and expansion valve ports. 18. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 19. Install the rear A/C expansion valve (3) onto the tapping plate located on the end of the rear evaporator tubes (2) 20. Install two bolts (1) that secure the rear A/C expansion valve to the taping plate. Tighten the bolts to 11 Nm (97 in. lbs.). 21. Position the flange (1) to the bottom of the rear heater-A/C housing (3) and install the three retaining screws (2). Tighten the screws to 1.2 Nm (10 in. lbs.). 22. Install the foam seal (2) onto the flange (1) at the bottom of the rear heater-A/C housing (3). Make sure that the foam seal is properly installed. 23. Install the rear blower motor . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7355 24. Install the rear blower motor resistor or power module (depending on application) or See: Control Module HVAC/Service and Repair/Rear Blower Motor Power Module - Installation. 25. Install the rear heater-A/C housing See: Removal and Replacement/Rear HVAC Housing Installation. 26. Reconnect the negative battery cable. 27. If the rear heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 28. If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Front A/C Receiver Drier - Description Receiver Dryer: Description and Operation Front A/C Receiver Drier - Description DESCRIPTION The A/C receiver/drier (1) stores unused refrigerant, filters the refrigerant, helps remove moisture from the refrigerant and retains any refrigerant vapor that may leave the A/C condenser until it becomes a liquid. The A/C receiver/drier is installed on the high-side of the A/C system, below the engine compartment behind the right side of the front fascia and is connected to the right side of the A/C condenser by an integral refrigerant line (2). An integral mounting bracket (5) secures the A/C receiver/drier to the right front frame rail and the connections are sealed by use of rubber O-ring seals (3) and metal gaskets (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Front A/C Receiver Drier - Description > Page 7360 Receiver Dryer: Description and Operation Front A/C Receiver Drier - Operation OPERATION The A/C receiver/drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the A/C expansion valve. Refrigerant enters the A/C receiver/drier as a high-pressure, low temperature liquid. Desiccant inside the A/C receiver/drier absorbs any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand operation of the A/C system, the A/C receiver/drier acts as a reservoir to store surplus refrigerant. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C receiver/drier has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C receiver/drier is disconnected. The A/C receiver/drier cannot be repaired and must be replaced if leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal Receiver Dryer: Service and Repair Front A/C Receiver Drier - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury. NOTE: LHD model shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Remove the nut (5) that secures the A/C liquid line (4) to the tapping block (2) located on the right side of the A/C condenser. 4. Disconnect the A/C liquid line from the tapping block and remove and discard the O-ring seal and gasket. 5. Install plugs in, or tape over the opened refrigerant line fitting and condenser port. 6. Raise and support the vehicle. 7. Position the front portion of the right front wheelhouse splash shield out of the way to gain access to the A/C receiver/drier See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 8. Remove the nut (2) that secures the lower A/C suction line (3) to the upper A/C suction line (1). 9. Disconnect the lower A/C suction line to the upper A/C suction line and remove and discard the O-ring seal and gasket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal > Page 7363 NOTE: Illustration shown with front fascia and headlamp removed for clarity. 10. Remove the bolt (3) that secures the rear section of the A/C suction line (1) to the right front frame rail (2) and position the suction line out of the way. 11. Remove the nut (6) that secures the rear section of the A/C liquid line (7) to the A/C receiver/drier (4). 12. Disconnect the rear section of the A/C liquid line from the A/C receiver/drier, remove and discard the O-ring seal and gasket and position the liquid line out of the way. 13. Remove the bolt (5) that secure the A/C receiver/drier to the right front frame rail and remove the receiver/drier. 14. Install plugs in, or tape over all of the opened refrigerant line fittings and the receiver/drier port. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal > Page 7364 Receiver Dryer: Service and Repair Front A/C Receiver Drier - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred See: Front A/C Receiver Drier Removal . Failure to replace the A/C Receiver Drier can cause serious damage to the replacement A/C compressor. NOTE: If only the A/C receiver/drier is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. NOTE: Illustration shown with front fascia and headlamp removed for clarity. 1. Position the A/C receiver/drier (4) to the right front frame rail (2) and loosely install the lower retaining bolt (5). 2. Install the bolt (3) that secures the upper portion of the A/C suction line (1) to the right front frame rail. Tighten both bolts securely. 3. Remove the tape or plugs from the opened refrigerant line fittings and the receiver/drier port. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the rear section of the A/C liquid line (7) to the A/C receiver/drier. 6. Install the nut (6) that secures the rear section of the A/C liquid line to the A/C receiver/drier. Tighten the nut to 20 Nm (15 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal > Page 7365 7. Connect the lower portion of the A/C suction line (3) to the upper suction line (1) 8. Install the nut (2) that secures the lower portion of the A/C suction line to the upper suction line. Tighten the nut to 20 Nm (15 ft. lbs.). 9. Reposition the right front wheel house splash shield to the body See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 10. Lower the vehicle. 11. Remove the tape or plug from the opened refrigerant line fitting and condenser ports. 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gaskets onto the refrigerant line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the A/C liquid line (4) to the tapping block (2) and install the retaining nut (5). Tighten the nut to 20 Nm (15 ft. lbs.). 14. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 15. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate 16. If the A/C condenser is being replaced, add 10 milliliters (0.3 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 17. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE CAPACITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7370 Refrigerant: Fluid Type Specifications Type...................................................................................................................................................... .........................................................................R-134a Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Refrigerant - Description Refrigerant: Description and Operation Refrigerant - Description A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a nontoxic, nonflammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Testing and Inspection/Component Tests and General Diagnostics. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Refrigerant - Description > Page 7373 Refrigerant: Description and Operation Refrigerant - Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the poly alkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: If equipped with the rear heating-A/C system, use a heat gun to heat the underbody lines to help remove any trapped refrigerant from the rear A/C system. When servicing the A/C system, a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 must be used (1). Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 7376 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Service and Repair/Refrigerant System Recovery. 2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Service and Repair/Refrigerant System Recovery. Do not operate the engine with a vacuum on the A/C system. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 7377 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system See: Specifications/Capacity Specifications. When charging the A/C system, a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 must be used (1). Per SAE standard J2788, refrigerant recovery stations must charge the system to an accuracy of 14 grams (0.5 oz.). Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. See the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 2. Connect a manifold gauge set or R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible serious or fatal injury. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7382 Refrigerant Oil: Fluid Type Specifications Type...................................................................................................................................................... ..................................................................ND-8 PAG Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description Refrigerant Oil: Description and Operation Refrigerant Oil - Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, poly alkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available and each contain a different additive package. Always use only the type of refrigerant oil recommended for the A/C compressor in the vehicle. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. The A/C compressors used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description > Page 7385 Refrigerant Oil: Description and Operation Refrigerant Oil - Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 7386 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Drain the refrigerant oil from the A/C compressor using the procedures described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. CAUTION: ND-8 PAG refrigerant oil is used in the A/C system. Only refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C receiver/drier, A/C evaporator or A/C condenser is replaced. Refer to the Refrigerant Oil Capacities charts. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. Refer to the following COMPRESSOR OIL DRAIN PROCEDURE. REFRIGERANT OIL CAPACITIES COMPRESSOR OIL DRAIN PROCEDURE - DENSO 6SEU16 VARIABLE DISPLACEMENT CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 6SEU16 A/C compressor can only be drained using the procedure described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. If the Denso 6SEU16 A/C compressor is being replaced, some refrigerant oil must first be drained from the replacement A/C compressor. The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 50 milliliters (1.7 oz.) of refrigerant oil from the replacement 6SEU16 compressor. Use the following procedure to drain and measure refrigerant oil from the Denso 6SEU16 A/C compressor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 7387 1. Place the replacement A/C compressor (2) on a workbench and remove the drain plug (1). CAUTION: The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 50 milliliters (1.7 oz.) of refrigerant oil from the new 6SEU16 compressor when replacing only the compressor. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be removed from the replacement A/C compressor (example: new 6SEU16 compressor and receiver/drier requires 80 ml. (2.7 oz.) of oil to be added to the system. 100 ml. (3.4 oz.) of oil is in replacement compressor. 100 ml. (3.4 oz.) minus 80 ml. (2.7 oz.) equals 20 ml. (0.7 oz.) oil to be drained from replacement compressor). 2. Position the replacement A/C compressor so that the refrigerant oil can drain out of the drain port into a suitable clean measured container. Hold the replacement A/C compressor in this position until the required amount of refrigerant oil is drained from the compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 3. Reinstall the drain plug. Tighten the drain plug securely. 4. Install the replacement A/C compressor onto the engine See: Compressor HVAC/Service and Repair/A/C Compressor Installation. COMPRESSOR OIL DRAIN PROCEDURE - DENSO 10SR15 AND 10SR17 FIXED DISPLACEMENT CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 7388 The Denso 10SR15 and 10SR17 A/C compressors are filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the Denso 10SR15 and 10SR17 A/C compressors. 1. Position the original A/C compressor so that the refrigerant oil can drain out of the suction and discharge ports into a suitable clean measured container. Hold the original A/C compressor in this position until all of the refrigerant oil is drained from the compressor. 2. Drain all of the refrigerant oil from the replacement A/C compressor into a clean measured container. 3. Refill the replacement A/C compressor with the same amount of refrigerant oil that was drained out of the original compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. See: Compressor HVAC/Service and Repair/A/C Compressor - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7392 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (HEADLAMP AND DASH) 4 WAY TRANSDUCER-A/C PRESSURE - (HEADLAMP AND DASH) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C liquid line at the right front corner of the engine compartment. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting. A rubber O-ring seals the connection between the A/C pressure transducer and the A/C liquid line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description > Page 7395 Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the Powertrain Control Module (PCM) or the Engine Control Module (ECM) (depending on engine application) over the CAN C BUS. With 3.5L 5-Passenger and all 7-Passenger models, the PCM is programmed to respond to this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. With 2.4L 5-Passenger models, A/C compressor clutch engagement is controlled by the PCM or ECM, depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-IHS bus to the TIPM, which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the TIPM to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C liquid line (3) at the right front corner of the engine compartment. 3. Remove the A/C pressure transducer from the A/C liquid line and remove and discard the O-ring seal (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal > Page 7398 Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C liquid line (3). 2. Install the A/C pressure transducer (2) onto the A/C liquid line. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 > Page 7404 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Auxiliary Heater Element Relay > Component Information > Locations > Cabin Heater Relay 1 > Page 7405 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 7409 Blower Motor Relay: Diagrams Connector (3 ZONE HVAC) - (IN TIPM) 5 WAY RELAY-REAR BLOWER MOTOR (3 ZONE HVAC) - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF Control Module HVAC: Customer Interest A/C - Airflow From Vents With A/C OFF NUMBER: 24-008-08 GROUP: Air Conditioning DATE: September 4, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.01 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Airflow Through HVAC Ducts with System Off OVERVIEW: This Bulletin involves reprogramming the Three Zone Manual Temperature Control module with new software. MODELS: 2008 (RT) Grand Caravan/Town & Country 2009 (JC) Journey NOTE: This bulletin applies to RT equipped with 3 zone manual A/C (Sales Code HAG) built prior to April 16, 2008 (MDH0416XX) at Windsor Assembly plant (R in 11th VIN position) -OR- April 22, 2008 (MDH0422XX) at the St. Louis Assembly plant (B in 11th VIN position) NOTE: This bulletin applies to JC equipped with 3 zone manual A/C (Sales Code HAG) built before June 15, 2008 (MDH0615XX). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is noticeable while driving with the HVAC system off. This may be more noticeable with the temperature settings at medium or higher heat settings due to the temperature differential coming out of the ducts. Turning the blower on, and then off will force the fresh air/recirculation door closed eliminating the airflow. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C Systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 9.01 level software or higher. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7418 software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home" screen: a.Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7419 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF Control Module HVAC: All Technical Service Bulletins A/C - Airflow From Vents With A/C OFF NUMBER: 24-008-08 GROUP: Air Conditioning DATE: September 4, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.01 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Airflow Through HVAC Ducts with System Off OVERVIEW: This Bulletin involves reprogramming the Three Zone Manual Temperature Control module with new software. MODELS: 2008 (RT) Grand Caravan/Town & Country 2009 (JC) Journey NOTE: This bulletin applies to RT equipped with 3 zone manual A/C (Sales Code HAG) built prior to April 16, 2008 (MDH0416XX) at Windsor Assembly plant (R in 11th VIN position) -OR- April 22, 2008 (MDH0422XX) at the St. Louis Assembly plant (B in 11th VIN position) NOTE: This bulletin applies to JC equipped with 3 zone manual A/C (Sales Code HAG) built before June 15, 2008 (MDH0615XX). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is noticeable while driving with the HVAC system off. This may be more noticeable with the temperature settings at medium or higher heat settings due to the temperature differential coming out of the ducts. Turning the blower on, and then off will force the fresh air/recirculation door closed eliminating the airflow. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C Systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 9.01 level software or higher. The Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7425 software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home" screen: a.Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-008-08 > Sep > 08 > A/C - Airflow From Vents With A/C OFF > Page 7426 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7427 Control Module HVAC: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7428 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way Control Module HVAC: Diagrams Front Blower Module (ATC) (Instrument Panel) 4 Way Connector (ATC) - (INSTRUMENT PANEL) 4 WAY MODULE-BLOWER-FRONT (ATC) - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way > Page 7431 Control Module HVAC: Diagrams Rear Blower Module C1 (3 Zone ATC) (Body) 6 Way Connector C1 (3 ZONE ATC) - (BODY) 6 WAY MODULE-BLOWER-REAR (3 ZONE ATC) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Module (ATC) (Instrument Panel) 4 Way > Page 7432 Control Module HVAC: Diagrams Rear Blower Module C2 (3 Zone ATC) (Body) 2 Way Connector C2 (3 ZONE ATC) - (BODY) 2 WAY MODULE-BLOWER-REAR (3 ZONE ATC) - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description Control Module HVAC: Description and Operation Front Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module . The blower motor power module is mounted to the bottom of the HVAC housing, on the passenger side of the vehicle. The blower motor power module consists of a molded plastic mounting plate (1) with an integral connector receptacle (2). Concealed behind the mounting plate is the power module electronic circuitry (3) and a finned aluminum heat sink (4). The blower motor power module is accessed for service from under the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7435 Control Module HVAC: Description and Operation Front Blower Motor Power Module - Operation OPERATION The blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the instrument panel wire harness. A second lead and connector of the instrument panel wire harness is connected to the blower motor. The blower motor power module allows the microprocessor-based automatic temperature control(ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7436 Control Module HVAC: Description and Operation Rear Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) rear heating-A/C system. Models equipped with the manual temperature control (MTC) rear heating-A/C system use a blower motor resistor, instead of the blower motor power module . The rear blower motor power module (1) is mounted to the inboard side of the rear heating-A/C housing, located on the right side of the vehicle. The rear blower motor power module consists of a molded plastic housing with two integral wire connector receptacles (2) for the power module electronic circuitry, a mounting plate (3) with a gasket and a finned aluminum heat sink (4). The rear blower motor power module can be accessed for service without removing the rear heater-A/C housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7437 Control Module HVAC: Description and Operation Rear Blower Motor Power Module - Operation OPERATION The rear blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the rear body wire harness. A second lead and connector of the wire harness is connected to the rear blower motor. The rear blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the rear blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The rear blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal Control Module HVAC: Service and Repair Front Blower Motor Power Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heat sink for the blower motor power module may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor power module, wait five minutes to allow the heat sink to cool before performing diagnosis or service. Failure to take this precaution may result in possible serious injury. NOTE: LHD model shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the blower motor power module (2) located at the bottom of the HVAC housing (3) on the passenger side of the vehicle. 3. Remove the two screws (4) that secure the blower motor power module to the HVAC housing and remove the power module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7440 Control Module HVAC: Service and Repair Front Blower Motor Power Module - Installation INSTALLATION NOTE: LHD model shown. 1. Position the blower motor power module (2) into the bottom of the HVAC housing (3). 2. Install the two screws (4) that secure the blower motor power module to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor power module. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7441 Control Module HVAC: Service and Repair Rear Blower Motor Power Module - Installation INSTALLATION 1. Position the rear blower motor power module (3) onto the rear heater-A/C housing (2). 2. Install the two screws (1) that secure the rear blower motor power module to the rear heater-A/C housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the two wire harness connectors (4) to the rear blower motor power module. 4. Install the right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7442 Control Module HVAC: Service and Repair Rear Blower Motor Power Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the two wire harness connectors (4) from the rear blower motor power module (3). 4. Remove the two screws (1) that secure the rear blower motor power module to the rear heater-A/C housing (2) and remove the module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7447 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (FRONT END MODULE) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Description DESCRIPTION The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ATC system uses the sensor data to maintain optimum cabin temperature levels. The ambient air temperature sensor is mounted inside the front fascia. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description > Page 7450 Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Operation OPERATION The ambient air temperature sensor is a variable resistor that operates on a 5-volt reference signal sent by the Totally Integrated Power Module (TIPM). The ambient air temperature sensor is connected to the TIPM through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes its internal resistance in response to changes in the outside air temperature, which either increases or decreases the reference signal voltage read by the TIPM. The TIPM converts and broadcasts the sensor data over the Controller Area Network (CAN) IHS bus, where it is read by the ATC A/C-heater control, Powertrain Control Module (PCM) and other vehicle control modules. The ambient air temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7454 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7455 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7456 Evaporator Temperature Sensor / Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SENSOR-EVAPORATOR TEMPERATURE - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor Description Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor Description > Page 7459 Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing See: Compressor HVAC/Description and Operation/A/C Compressor - Operation. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal > Page 7462 Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7466 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (HEADLAMP AND DASH) 4 WAY TRANSDUCER-A/C PRESSURE - (HEADLAMP AND DASH) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C liquid line at the right front corner of the engine compartment. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting. A rubber O-ring seals the connection between the A/C pressure transducer and the A/C liquid line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description > Page 7469 Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the Powertrain Control Module (PCM) or the Engine Control Module (ECM) (depending on engine application) over the CAN C BUS. With 3.5L 5-Passenger and all 7-Passenger models, the PCM is programmed to respond to this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. With 2.4L 5-Passenger models, A/C compressor clutch engagement is controlled by the PCM or ECM, depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-IHS bus to the TIPM, which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the TIPM to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C liquid line (3) at the right front corner of the engine compartment. 3. Remove the A/C pressure transducer from the A/C liquid line and remove and discard the O-ring seal (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal > Page 7472 Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C liquid line (3). 2. Install the A/C pressure transducer (2) onto the A/C liquid line. Tighten the A/C pressure transducer to 5.6 Nm (50 in. lbs.). 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) > Page 7477 Solar Sensor: Locations Sun Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) > Page 7478 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (ATC) (Headliner) 4 Way Solar Sensor: Diagrams Infrared Sensor (ATC) (Headliner) 4 Way Connector (ATC) - (HEADLINER) 4 WAY SENSOR-INFRARED (ATC) - (HEADLINER) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (ATC) (Headliner) 4 Way > Page 7481 Solar Sensor: Diagrams Sun Sensor (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-SUN - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description Solar Sensor: Description and Operation Infrared Temperature Sensor - Description DESCRIPTION The infrared temperature sensor is located in the overhead console and consists of an infrared transducer concealed behind a clear lens (2) in a molded plastic housing with an integral wire connector receptacle (1) and mounting tab (3). The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heating-A/C system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7484 Solar Sensor: Description and Operation Infrared Temperature Sensor - Operation OPERATION The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and surroundings and converts its data into a linear Pulse Width Modulated (PWM) output signal which is read by the Automatic Temperature Control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature levels. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store Diagnostic Trouble Codes (DTCs) for any problem it detects. The infrared sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7485 Solar Sensor: Description and Operation Sun Sensor - Description DESCRIPTION NOTE: Typical sun sensor assembly shown. The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7486 Solar Sensor: Description and Operation Sun Sensor - Operation OPERATION The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side variations in sun light intensity. Passengers in sun and shadow require different functional settings because they experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic headlight control, if equipped. The sun sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 7487 Solar Sensor: Testing and Inspection SUN SENSOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in an accidental airbag deployment and possible serious or fatal injury. The sun sensor assembly is located so that the sun rays will hit the sensors in the same way that it will hit the driver and the passenger. It is important that the area in front of the sun sensor assembly be unobstructed. Check for the following: - Windshield wipers are properly adjusted. - Defroster grille or sun sensor is properly installed. The sun sensor lens should protrude above the defroster grille. - Any stickers on the windshield are not directly in front of the sun sensor. - Any items laying on top of the instrument panel are not covering the sun sensor. If the vehicle exhibits a lack of passenger comfort in sunny weather such as in the early afternoon, inspect the position of the sun sensor assembly. The sun sensor lens should protrude above the defroster grille to insure proper operation. If the sun sensor is not properly positioned, perform the following procedure: 1. Confirm that the defroster grille is properly installed. If not, repair as required. 2. Remove the defroster grille and verify that the sun sensor is properly installed to the instrument panel See: Service and Repair/Sun Sensor Installation. 3. Reinstall the defroster grille. The A/C-heater control continually monitors the sun sensor circuits and will store diagnostic trouble codes (DTCs) for any problem it detects. The sun sensor can be tested in the vehicle with a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal Solar Sensor: Service and Repair Infrared Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Using Trim Stick C-4755 or equivalent, carefully disengage the four retaining tabs (1) that secure the infrared sensor and overhead map/courtesy lamp bezel (2) to the overhead console (3). 3. Disconnect the wire harness connectors (4) from the two overhead map/courtesy lamps (5) and the infrared sensor (6) and remove the sensor, lamp and bezel assembly from the vehicle Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7490 Solar Sensor: Service and Repair Infrared Temperature Sensor - Installation INSTALLATION 1. Position the infrared sensor and overhead map/courtesy lamp bezel (2) to the overhead console (3). 2. Connect the wire harness connectors (4) to the two overhead map/courtesy lamps (5) and the infrared sensor (6). 3. Engage the four retaining tabs (1) that secure the infrared sensor and overhead map/courtesy lamp bezel to the overhead console. Make sure the retaining tabs are fully engaged. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7491 Solar Sensor: Service and Repair Sun Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille See: Air Register/Service and Repair/Defroster Grille - Removal. 3. Using Trim Stick C-4755 or equivalent (2), gently pry between both sides of the sun sensor assembly (1) and the instrument panel (3) to release the snap retainers that secure the sun sensor. 4. Disconnect the wire harness connector (2) from the sun sensor assembly (1) and remove the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7492 Solar Sensor: Service and Repair Sun Sensor - Installation INSTALLATION 1. Position the sun sensor assembly (1) to the top of the instrument panel (4) and connect the wire harness connector (3). 2. Align the tab (2) on the sun sensor assembly with the opening in the instrument panel. 3. Gently push the sun sensor assembly into the instrument panel until the sensor snap retainers are securely engaged. 4. Install the defroster grille See: Air Register/Service and Repair/Defroster Grille - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation DESCRIPTION Refrigerant system service ports are used to recover, recycle, evacuate, charge and test the A/C refrigerant system. Unique sizes are used on the two service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or by service equipment used for R-12 refrigerant. The high side service port is located on the A/C liquid line near the right front strut tower. The low side service port is located on the A/C suction line near the dash panel. Both the high side and low side A/C service port valve cores are serviceable. NOTE: The protective cap aids in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective caps onto the service ports when refrigerant system service is complete. Each of the service ports has a threaded plastic protective cap installed over it from the factory. The service port caps are serviceable items. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Front Service Port Valve Core - Removal Service Port HVAC: Service and Repair Front Service Port Valve Core - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: Typical A/C service port shown. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in, or tape over the opened service port(s). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Front Service Port Valve Core - Removal > Page 7498 Service Port HVAC: Service and Repair Front Service Port Valve Core - Installation INSTALLATION NOTE: Typical A/C service port shown. 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage. 4. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 5. Install the protective cap (1) onto the service port. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) > Page 7503 Solar Sensor: Locations Sun Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor (ATC) > Page 7504 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (ATC) (Headliner) 4 Way Solar Sensor: Diagrams Infrared Sensor (ATC) (Headliner) 4 Way Connector (ATC) - (HEADLINER) 4 WAY SENSOR-INFRARED (ATC) - (HEADLINER) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (ATC) (Headliner) 4 Way > Page 7507 Solar Sensor: Diagrams Sun Sensor (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-SUN - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description Solar Sensor: Description and Operation Infrared Temperature Sensor - Description DESCRIPTION The infrared temperature sensor is located in the overhead console and consists of an infrared transducer concealed behind a clear lens (2) in a molded plastic housing with an integral wire connector receptacle (1) and mounting tab (3). The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heating-A/C system. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7510 Solar Sensor: Description and Operation Infrared Temperature Sensor - Operation OPERATION The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and surroundings and converts its data into a linear Pulse Width Modulated (PWM) output signal which is read by the Automatic Temperature Control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature levels. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store Diagnostic Trouble Codes (DTCs) for any problem it detects. The infrared sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7511 Solar Sensor: Description and Operation Sun Sensor - Description DESCRIPTION NOTE: Typical sun sensor assembly shown. The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7512 Solar Sensor: Description and Operation Sun Sensor - Operation OPERATION The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side variations in sun light intensity. Passengers in sun and shadow require different functional settings because they experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic headlight control, if equipped. The sun sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Page 7513 Solar Sensor: Testing and Inspection SUN SENSOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in an accidental airbag deployment and possible serious or fatal injury. The sun sensor assembly is located so that the sun rays will hit the sensors in the same way that it will hit the driver and the passenger. It is important that the area in front of the sun sensor assembly be unobstructed. Check for the following: - Windshield wipers are properly adjusted. - Defroster grille or sun sensor is properly installed. The sun sensor lens should protrude above the defroster grille. - Any stickers on the windshield are not directly in front of the sun sensor. - Any items laying on top of the instrument panel are not covering the sun sensor. If the vehicle exhibits a lack of passenger comfort in sunny weather such as in the early afternoon, inspect the position of the sun sensor assembly. The sun sensor lens should protrude above the defroster grille to insure proper operation. If the sun sensor is not properly positioned, perform the following procedure: 1. Confirm that the defroster grille is properly installed. If not, repair as required. 2. Remove the defroster grille and verify that the sun sensor is properly installed to the instrument panel See: Service and Repair/Sun Sensor Installation. 3. Reinstall the defroster grille. The A/C-heater control continually monitors the sun sensor circuits and will store diagnostic trouble codes (DTCs) for any problem it detects. The sun sensor can be tested in the vehicle with a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal Solar Sensor: Service and Repair Infrared Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Using Trim Stick C-4755 or equivalent, carefully disengage the four retaining tabs (1) that secure the infrared sensor and overhead map/courtesy lamp bezel (2) to the overhead console (3). 3. Disconnect the wire harness connectors (4) from the two overhead map/courtesy lamps (5) and the infrared sensor (6) and remove the sensor, lamp and bezel assembly from the vehicle Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7516 Solar Sensor: Service and Repair Infrared Temperature Sensor - Installation INSTALLATION 1. Position the infrared sensor and overhead map/courtesy lamp bezel (2) to the overhead console (3). 2. Connect the wire harness connectors (4) to the two overhead map/courtesy lamps (5) and the infrared sensor (6). 3. Engage the four retaining tabs (1) that secure the infrared sensor and overhead map/courtesy lamp bezel to the overhead console. Make sure the retaining tabs are fully engaged. 4. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7517 Solar Sensor: Service and Repair Sun Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille See: Air Register/Service and Repair/Defroster Grille - Removal. 3. Using Trim Stick C-4755 or equivalent (2), gently pry between both sides of the sun sensor assembly (1) and the instrument panel (3) to release the snap retainers that secure the sun sensor. 4. Disconnect the wire harness connector (2) from the sun sensor assembly (1) and remove the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7518 Solar Sensor: Service and Repair Sun Sensor - Installation INSTALLATION 1. Position the sun sensor assembly (1) to the top of the instrument panel (4) and connect the wire harness connector (3). 2. Align the tab (2) on the sun sensor assembly with the opening in the instrument panel. 3. Gently push the sun sensor assembly into the instrument panel until the sensor snap retainers are securely engaged. 4. Install the defroster grille See: Air Register/Service and Repair/Defroster Grille - Installation. 5. Reconnect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT Any vehicle which is to be returned to use following a Supplemental Restraint System (SRS) component deployment must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring must be replaced and the steering column must be inspected. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection. If the passenger airbag is deployed, the instrument panel top pad must be replaced. The seat belt tensioners are deployed in conjunction with front airbags, but can also be deployed with seat (thorax) or side airbags. The seat belt tensioners must be replaced if either front airbag has been deployed, and must be inspected if either seat or side airbag has been deployed. If a seat airbag is deployed, the seat back frame, the seat back foam and the seat back trim cover on the same side of the vehicle as the deployed airbag must also be replaced. If a side curtain airbag has been deployed, the headliner as well as the upper A, B, C and, on vehicles with the optional seven-passenger seating, the D-pillar trim on the same side of the vehicle as the deployed airbag must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a SRS component deployment, which may or may not be obvious during a visual inspection. On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected following a side curtain airbag deployment. It is also critical that the mounting surfaces and mounting brackets for the Occupant Restraint Controller (ORC), side impact sensors and front impact sensors be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ORC and each impact sensor are used by the SRS to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required. There are two methods by which an airbag or seat belt tensioner may be connected to the vehicle electrical system. The first method involves a short pigtail harness and connector insulator that are integral to the airbag or tensioner unit and are replaced as a unit with the service replacement airbag or seat belt tensioner unit. The second method involves a wire harness takeout and connector insulator (squib circuits) that are connected directly to the air bag or tensioner initiator. The heat created by the initiator during an airbag or tensioner deployment will cause collateral damage to a directly connected wire harness take out and connector insulator. Therefore, these direct-connect type take outs and connector insulators must be repaired following an airbag or seat belt tensioner deployment. See: Service and Repair. All other vehicle components should be closely inspected following any SRS component deployment, but are to be replaced only as required by the extent of the visible damage incurred. AIRBAG SQUIB STATUS Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this vehicle are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to the Hazardous Substance Control System for information regarding the potentially hazardous properties of the subject component and the proper safe handling procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local and federal regulations. 1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. 2. Turn the ignition switch to the ON position. 3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver and passenger airbag squibs. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 7523 NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the squibs were both live. CLEANUP PROCEDURE Following a Supplemental Restraint System (SRS) component deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a SRS component. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: To avoid serious or fatal injury, if you experience skin irritation during cleanup, run cool water over the affected area. Also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 7524 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to AIRBAG SQUIB STATUS. All damaged, ineffective, or non-deployed Supplemental Restraint System (SRS) components which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is ineffective or damaged and non-deployed, refer to the Hazardous Substance Control System for information regarding the potentially hazardous properties of the subject component and the proper safe handling procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed SRS components from the vehicle. Refer to the appropriate service removal procedures. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls for Air Bag Harness: > NHTSA09V118000 > Apr > 09 > Recall 09V118000: Air Bag Wiring Defect Air Bag Harness: Recalls Recall 09V118000: Air Bag Wiring Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 Jeep/Commander 2009 Jeep/Grand Cherokee 2009 Jeep/Wrangler 4-DR 4X4 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: April 07, 2009 NHTSA CAMPAIGN ID NUMBER: 09V118000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System: Wiring POTENTIAL NUMBER OF UNITS AFFECTED: 4336 SUMMARY: Chrysler is recalling 4,336 M/Y 2009 Dodge Journey, Jeep Grand Cherokee, Commander and Wrangler Vehicles. Wiring may be reversed on the steering column control module driver airbag squib connector. The driver's airbag may not deploy as intended. CONSEQUENCE: In the event of a crash, the driver's airbag may not properly inflate and may not be able to properly protect an occupant, increasing the risk of injuries. REMEDY: Dealers will inspect the driver's airbag squib wires and replace the steering column control module free of charge. The recall is expected to begin during May 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J13. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > NHTSA09V118000 > Apr > 09 > Recall 09V118000: Air Bag Wiring Defect Air Bag Harness: All Technical Service Bulletins Recall 09V118000: Air Bag Wiring Defect VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 Jeep/Commander 2009 Jeep/Grand Cherokee 2009 Jeep/Wrangler 4-DR 4X4 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: April 07, 2009 NHTSA CAMPAIGN ID NUMBER: 09V118000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System: Wiring POTENTIAL NUMBER OF UNITS AFFECTED: 4336 SUMMARY: Chrysler is recalling 4,336 M/Y 2009 Dodge Journey, Jeep Grand Cherokee, Commander and Wrangler Vehicles. Wiring may be reversed on the steering column control module driver airbag squib connector. The driver's airbag may not deploy as intended. CONSEQUENCE: In the event of a crash, the driver's airbag may not properly inflate and may not be able to properly protect an occupant, increasing the risk of injuries. REMEDY: Dealers will inspect the driver's airbag squib wires and replace the steering column control module free of charge. The recall is expected to begin during May 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J13. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7543 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way Air Bag Control Module: Diagrams Occupant Restraint Controller (Instrument Panel) 12 Way C2-A Connector - (INSTRUMENT PANEL) 12 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY C2-B Connector - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7546 MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7547 Air Bag Control Module: Diagrams Occupant Restraint Controller (Body) 36 Way C1-A Connector - (BODY) 36 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7548 C1-B Connector - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7549 MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7550 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7551 Air Bag Control Module: Diagrams Occupant Restraint Controller Module (Instrument Panel) 12 Way C2-A Connector - (INSTRUMENT PANEL) 12 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY C2-B Connector - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7552 MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7553 Air Bag Control Module: Diagrams Occupant Restraint Controller Module (Body) 36 Way C1-A Connector - (BODY) 36 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7554 C1-B Connector - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7555 MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7556 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the base of the dash panel and just forward on the center instrument panel support in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, electronic impact sensors and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with five screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label (2) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has three integral mounting tabs and two integral locating pins. The molded plastic electrical connector (3), with two receptacles containing numerous terminal pins, exits the rearward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one from the body wire harness and one from the instrument panel wire harness. The impact sensors internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without side curtain airbags or seat (thorax) airbags, with or without third row seating as well as for those vehicles with domestic or export applications. These variations are necessary for both equipment needs and for compliance with certain regulatory requirements. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 7559 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness that is secured by a ground screw to the body sheet metal. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Various impact sensors within the ORC are continuously monitored by the ORC logic. These internal sensors, along with several external impact sensor inputs allow the ORC to determine both the severity of an impact and to verify the necessity for deployment of any airbags. Two remote front impact sensors are located on the back of the front end module carrier to the right and left of the cooling module near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The ORC also monitors inputs from an internal rollover sensor and up to six additional remote side impact sensors located on the left and right front door module carriers, on the right and left lower C-pillars and, on vehicles equipped with optional third row seating, on the right and left quarter inner panels to control deployment of the side curtain airbag units and seat (thorax) airbags. The impact sensors within the ORC are electronic accelerometer sensors that provide an additional logic input to the ORC microprocessor. These sensors are used to verify the need for a SRS component deployment by also detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. On vehicles equipped with side curtain airbags or seat airbags, a separate impact sensor within the ORC provides confirmation to the ORC microprocessor of side impact forces. This separate sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners, the seat airbags and either side curtain airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the mini console from the top of the floor panel transmission tunnel (3). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Removal. 3. First disconnect the instrument panel wire harness connector (4), followed by the body wire harness connector (5) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm to the fully open position on each connector. 4. Remove the three screws (1) that secure the ORC to the ORC bracket that is welded onto the top of the floor panel transmission tunnel. 5. Lift the ORC far enough to disengage the locating pins and remove the ORC from the bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 7562 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Carefully position the Occupant Restraint Controller (ORC) (2) to the ORC bracket that is welded onto the top of the floor panel transmission tunnel. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle and the locating pins on the bottom of the ORC will be engaged into the locating holes in the ORC bracket. 2. Install and tighten the three screws (1) that secure the ORC to the ORC bracket. Tighten the screws to 12.5 Nm (9 ft. lbs.). CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged. 3. First reconnect the body wire harness connector (5), followed by the instrument panel wire harness connector (4) to the ORC connector receptacles located on the rearward facing side of the module. Be certain that the latches on both connectors are each fully engaged. 4. Reinstall the mini console onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. NOTE: Service replacement ORC modules are shipped in a LOCKED OUT state and after installed will set a ORC UNLOCKED - ALL DEPLOYMENT DISABLED fault. Use a diagnostic scan tool to access the ORC module and go to the MISCELLANEOUS FUNCTIONS menu item to perform the MODULE INITIALIZATION procedure to erase the fault and initialize the new replacement ORC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Clockspring - Description Clockspring Assembly / Spiral Cable: Description and Operation Clockspring - Description DESCRIPTION The clockspring (3) for this vehicle is secured near the top of the steering column below the steering wheel. The clockspring also includes an integral, internal turn signal cancel cam and a Steering Angle Sensor (SAS) that are both serviced as a unit with the clockspring. The clockspring also supports the left (lighting) multi-function switch (1), the Steering Control Module (SCM) internal to the left multi-function switch housing (2), and the right (wiper) multi-function switch (6). Each of these switches and the jumper wire harness (5) between the two multi-function switches can be separated from and are serviced individually from the clockspring. The clockspring case includes integral tabs for mounting the unit with three screws to the steering column lock housing as well as integral provisions for mounting and supporting both multi-function switches. The multi-function switches are each secured to the clockspring with a single screw (7). The SAS within the clockspring includes an electronic circuit board and a microprocessor, which allows it to communicate with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The SAS circuitry, the clockspring, and the turn signal cancel cam are all contained within a flat, molded plastic case. The clockspring case includes three connector receptacles that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, two short pigtail wires with connectors, and a connector receptacle that faces toward the steering wheel. The lower surface of the rotor has an integral dowel or drive pin that also faces toward the steering wheel. Wound around the rotor spool within the case is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at two of the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacle on the hub of the clockspring rotor that face the steering wheel. The outer surface of the rotor hub rim within the clockspring case also has the integral lobes of the turn signal cancel cam. The service replacement clockspring is shipped pre-centered and with a molded plastic locking pin (4) installed. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed after the clockspring is installed on the steering column and the steering wheel is installed. See: Service and Repair/Procedures. The clockspring cannot be repaired. If the clockspring is ineffective, damaged, or if the driver airbag has been deployed, the clockspring/turn signal cancel cam/SAS unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Clockspring - Description > Page 7567 Clockspring Assembly / Spiral Cable: Description and Operation Clockspring - Operation OPERATION The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and certain electrical components mounted on or in the rotating steering wheel. On this vehicle the rotating electrical components include the driver airbag, the horn switch, the speed control switch, the remote radio switches and the Electronic Vehicle Information Center (EVIC) control switches, if the vehicle is so equipped. The clockspring is positioned and secured near the top of the steering column. The fixed connector receptacles on the back of the fixed clockspring case connect the clockspring to the vehicle electrical system through three take outs with connectors from the instrument panel wire harness. The turn signal cancel cam is integral to the rim of the clockspring rotor hub within the clockspring case so it also moves with the rotation of the steering wheel. Two short, black-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connected to the connector receptacle on the upper surface of the clockspring rotor complete circuits to the horn switch, the speed control switch and, if the vehicle is so equipped, to the optional remote radio switches and EVIC control switches on the steering wheel. The third connector receptacle is dedicated to the inputs and outputs of the Steering Angle Sensor (SAS) internal to the clockspring case. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the steering wheel is removed from the steering column, if the clockspring is removed from the steering column, or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the other steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed on a steering column, the clockspring centering procedure must be performed. See: Service and Repair/Procedures. Proper clockspring installation may be confirmed by viewing the SAS data using a diagnostic scan tool. The hard wired clockspring circuits as well as the hard wired inputs and outputs of the SAS may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SAS or the electronic controls or communication between other modules and devices that provide features of the Electronic Stability Program (ESP) or Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the SAS or the electronic controls and communication related to ESP or SRS operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures CLOCKSPRING CENTERING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. NOTE: When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other Chrysler vehicles, this SAS never requires calibration. However, upon each new ignition ON cycle, the steering wheel must be rotated slightly to initialize the SAS. NOTE: Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. NOTE: The clockspring may be centered and the rotor may be rotated freely once the steering wheel has been removed. 1. Place the front wheels in the straight-ahead position and inhibit the steering column shaft from rotation. 2. Remove the steering wheel from the steering shaft. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 3. Rotate the clockspring rotor (1) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. Turn the rotor slightly clockwise or counterclockwise as necessary so that the clockspring airbag pigtail wires (3) and connector receptacle are at the top and the dowel or drive pin (5) is at the bottom. 5. The clockspring is now centered. Secure the clockspring rotor to the clockspring case using a locking pin (2) or some similar device to maintain clockspring centering until the steering wheel is reinstalled on the steering column. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7570 Clockspring Assembly / Spiral Cable: Removal and Replacement Clockspring - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. NOTE: When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other Chrysler vehicles, this SAS never requires calibration. See: Procedures . NOTE: Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. 1. Place the front wheels in the straight ahead position and inhibit the steering column shaft from rotation. 2. Disconnect and isolate the battery negative cable. 3. Remove the steering wheel from the steering shaft. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until the steering wheel is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before the steering wheel is reinstalled. See: Procedures. 5. Move the steering column to the fully lowered position and leave the tilt release lever in the released (down) position. 6. Remove the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 7. Remove the right multi-function switch (3) from the clockspring (4). See: Sensors and Switches/Sensors and Switches - Wiper and Washer Systems/Wiper Switch/Service and Repair/Right Multifunction Switch - Removal. 8. Remove the left multi-function switch (5) from the clockspring. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. 9. Remove the three screws (1) that secure the clockspring to the steering column bracket (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7571 10. Pull the clockspring (1) away from the steering column far enough to access and disconnect the three instrument panel wire harness connectors (2) from the receptacles on the back of the clockspring case. 11. Remove the clockspring from the steering column. Clockspring - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. NOTE: When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other Chrysler vehicles, this SAS never requires calibration. See: Procedures . NOTE: Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7572 1. If a new clockspring (1) is being installed, transfer the multifunction switch jumper harness from the old clockspring or position a new jumper harness onto the new clockspring. 2. Carefully slide the clockspring down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors (2) to the receptacles on the back of the clockspring case. 3. Position the clockspring (4) onto the steering column bracket (2). 4. Install and tighten the three screws (1) that secure the clockspring to the bracket in the following sequence: lower right, upper left, upper right. Tighten the screws to 3 Nm (27 in. lbs.). NOTE: Use of an improper sequence when tightening the clockspring mounting screws may result in an audible ticking noise as the steering wheel is rotated. 5. Reinstall the left multi-function switch (5) onto the clockspring. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Installation. 6. Reinstall the right multi-function switch (3) onto the clockspring. See: Sensors and Switches/Sensors and Switches - Wiper and Washer Systems/Wiper Switch/Service and Repair/Right Multifunction Switch - Installation. 7. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Move the steering column back to the fully raised position and move the tilt release lever back to the locked (up) position. 9. Reinstall the steering wheel onto the steering column. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. 10. Remove the plastic locking pin that secures the clockspring rotor to the clockspring case to maintain clockspring centering. 11. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7577 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7578 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7579 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7580 Impact Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7581 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7582 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7583 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7584 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7585 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7586 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7587 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way Impact Sensor: Diagrams Left Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-LEFT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7590 Impact Sensor: Diagrams Right Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7591 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-LEFT 1 - (FRONT DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7592 Impact Sensor: Diagrams Left Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7593 Impact Sensor: Diagrams Left Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-LEFT - (FRONT END MODULE) 2 WAY Right Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7594 Left Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-LEFT 1 - (FRONT DOOR) 3 WAY Left Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7595 Right Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (FRONT DOOR) 3 WAY Right Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-RIGHT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7596 Left Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 2 WAY Right Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7597 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Vehicle Front VEHICLE FRONT Two acceleration-type front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the back of the front end module carrier on either outboard side of the cooling module, just inboard of each front lamp unit housing within the engine compartment. The sensor housing has an integral connector receptacle (3), an integral locating and anti-rotation pin, and an integral mounting hole (2). The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the front end module wire harness. These acceleration-type front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Front Door SIDE - FRONT DOOR Two pressure-type front door side impact sensors (2) are used on this vehicle when it is equipped with the side curtain airbags or the optional seat (also known as thorax) airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with two screws and is sealed by a resilient gasket (1) to the front door module carrier on the inside of the front door. The sensors are concealed behind the front door trim panel within the passenger compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7600 The right and left front door side impact sensors are identical in construction and calibration. The impact sensor housing has an integral connector receptacle (3), two integral mounting tabs, and an integral hood-like water shield (4) that extends through a hole in the front door module carrier into the interior of the door cavity and protects the sensor orifice from contamination. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor, which includes an electronic communication chip and the pressure sensor. The housing cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. A label on the sensor has a directional arrow and the word down imprinted upon it to provide verification of the correct sensor orientation in the vehicle. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the front door wire harness. These pressure-type front door side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Second Row Seating SIDE - SECOND ROW SEATING Two acceleration-type second row seating side impact sensors (1) are used on this vehicle when it is equipped with the side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the lower C-pillar just above the rear door opening sill within the passenger compartment. The sensor housing has an integral connector receptacle (3), an integral locating anti-rotation pin, and an integral mounting hole (2). The right and left second row seating side impact sensors are identical in construction and calibration. However, the connector orientation in the vehicle is reversed. The connector receptacle faces forward on the right side of the vehicle, and faces rearward on the left side of the vehicle. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The second row seating side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. These acceleration-type second row seating side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Third Row Seating SIDE - THIRD ROW SEATING Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7601 Two acceleration-type third row seating side impact sensors (1) are used on this vehicle when it is equipped with the side curtain airbags and seven-passenger seating, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left quarter inner panel just above the right or left rear wheel housing within the passenger compartment. The sensor housing has an integral connector receptacle (3), an integral locating anti-rotation pin, and an integral mounting hole (2). The right and left third row seating side impact sensors are identical in construction and calibration. However, the connector orientation in the vehicle is reversed. The connector receptacle faces forward on the right side of the vehicle, and faces rearward on the left side of the vehicle. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The third row seating side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. These acceleration-type third row seating side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7602 Impact Sensor: Description and Operation Impact Sensor - Operation Vehicle Front VEHICLE FRONT The acceleration-type front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the front passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and commands the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the sensor plus circuit. The hard wired circuits between the acceleration-type front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Front Door SIDE - FRONT DOOR The pressure-type front door side impact sensors recognize a side impact in the front door area by monitoring changes in pressure within the front door cavity, which manifests itself as a sudden pressure wave as the door collapses during an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the sensor plus circuit. The hard wired circuits between the pressure-type front door side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the pressure-type front door side impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Second Row Seating SIDE - SECOND ROW SEATING The acceleration-type second row seating side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the acceleration-type second row seating side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type second row seating side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Third Row Seating Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7603 SIDE - THIRD ROW SEATING The acceleration-type third row seating side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the acceleration-type third row seating side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type third row seating side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Vehicle Front VEHICLE FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Service access for the front impact sensors is accomplished by reaching behind the front end module carrier (2) from the top of the engine compartment and between the inboard end of either front lamp unit housing (3) and either outboard end of the cooling module. 3. For the left front impact sensor only, remove the fresh air intake snorkel and the air filter housing from behind the front end module carrier for service access. 4. Disconnect the front end module wire harness connector (5) from the connector receptacle of the right or left front impact sensor (1). 5. Remove the screw (4) that secures the front impact sensor to the back (engine compartment side) of the front end module carrier. 6. Pull the front impact sensor straight back from the mounting location to disengage the anti-rotation pin on the base of the sensor from the clearance hole in the front end module carrier. 7. Remove the right or left front impact sensor from the engine compartment. Side - Front Door SIDE - FRONT DOOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7606 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the trim panel from the inside of the right or left front door. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the front door wire harness connector (3) from the side impact sensor (1) connector receptacle. 4. Remove the two screws (2) that secure the side impact sensor to the front door module carrier panel (4). 5. Remove the side impact sensor from the door. Side - Second Row Seating SIDE - SECOND ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Open the sliding door. 3. Remove the quarter trim panel from the lower C-pillar (1).See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 4. Disconnect the body wire harness connector (4) from the side impact sensor (3) connector receptacle. 5. Remove the screw (2) that secures the side impact sensor to the lower C-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7607 6. Pull the side impact sensor straight out from the mounting location to unsnap the anti-rotation pin on the base of the sensor from the clearance hole in the lower C-pillar. 7. Remove the side impact sensor from the vehicle. Side - Third Row Seating SIDE - THIRD ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the quarter trim panel from the quarter inner panel over the rear wheel housing (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the body wire harness connector (2) from the side impact sensor (4) above the rear wheel housing on the quarter inner panel. 4. Remove the screw (3) that secures the side impact sensor to the quarter inner panel. 5. Pull the side impact sensor straight out from the mounting location to disengage the anti-rotation pin on the base of the sensor from the clearance hole in the quarter inner panel. 6. Remove the side impact sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7608 Impact Sensor: Service and Repair Impact Sensor - Installation Vehicle Front VEHICLE FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Service access for the front impact sensors is accomplished by reaching behind the front end module carrier (2) from the top of the engine compartment and between the inboard end of either front lamp unit housing (3) and either outboard end of the cooling module. 2. Position the right or left front impact sensor (1) into the engine compartment. 3. Align and insert the anti-rotation pin on the base of the sensor into the clearance hole on the back (engine compartment side) of the front end module carrier. 4. Install and tighten the screw (4) that secures the front impact sensor to the front end module carrier. Tighten the screw to 11 Nm (97 in. lbs.). 5. Reconnect the front end module wire harness connector (5) to the connector receptacle of the front impact sensor. 6. For the left front impact sensor only, reinstall the fresh air intake snorkel and the air filter housing behind the front end module carrier. 7. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - Front Door SIDE - FRONT DOOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7609 NOTE: Be certain that the gasket between the pressure-type side impact sensor and the front door module carrier panel is in good condition and positioned on the back of the sensor. There MUST be a good seal between the sensor and the module carrier panel for the sensor to operate properly. If the gasket is in poor condition, replace the sensor. 1. Position the side impact sensor (1) to the right or left front door module carrier panel (4). When the sensor is correctly positioned, the arrow on the sensor label will be pointed toward the bottom of the door. 2. Install and tighten the two screws (2) that secure the side impact sensor to the door. Tighten the screws to 2.4 Nm (21 in. lbs.). 3. Reconnect the front door wire harness connector (3) to the sensor connector receptacle. 4. Reinstall the trim panel onto the inside of the right or left front door. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - Second Row Seating SIDE - SECOND ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7610 1. Position the side impact sensor (3) to the lower C-pillar (1). 2. Align the anti-rotation pin on the base of the sensor with the clearance hole in the lower C-pillar, then press on the sensor firmly and evenly to snap the pin into place. 3. Install and tighten the screw (2) that secures the side impact sensor to the lower C-pillar. Tighten the screw to 11 Nm (97 in. lbs.). 4. Reconnect the body wire harness connector (4) to the side impact sensor on the lower C-pillar. 5. Reinstall the quarter trim panel onto the lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - Third Row Seating SIDE - THIRD ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Position the side impact sensor (4) to the quarter inner panel above the rear wheel housing (1). 2. Align the anti-rotation pin on the base of the sensor with the clearance hole in the quarter inner panel, then press on the sensor firmly and evenly to snap the pin into place. 3. Install and tighten the screw (3) that secures the side impact sensor to the quarter inner panel. Tighten the screw to 11 Nm (97 in. lbs.). 4. Reconnect the body wire harness connector (2) to the side impact sensor on the quarter inner panel. 5. Reinstall the quarter trim panel onto the quarter inner panel over the rear wheel housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver side front seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 7615 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC sends messages over the CAN data bus to control the illumination of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the rear edge of the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 7618 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the rear edge of the front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the blade of the sensor bracket (1) located on the inboard side near the rear of the upper inboard seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Removal Child Seat: Service and Repair Child Seat - Removal REMOVAL 1. Remove the appropriate seat cushion and place on a bench. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover Removal. 2. Unzip the seat cover. 3. Partially remove the seat cushion cover to gain access to the booster seat fasteners. 4. Remove the booster seat mounting fasteners. 5. Unlatch the booster seat and carefully place in the upright position. 6. Disengage the booster seat cover trim clips. 7. Remove the booster seat from the seat cushion. 8. If required, disengage the seat cover clips and carefully pull the booster seat cover off the foam. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Removal > Page 7623 Child Seat: Service and Repair Child Seat - Installation INSTALLATION 1. If required, carefully pull the booster seat cover over the foam and engage the booster seat cover clips. 2. Install the booster seat to the seat cushion. 3. Engage the booster seat cover trim clips. 4. Latch the booster seat. 5. Install the booster seat mounting fasteners. Tighten to 13 N-m (10 ft. lbs.). 6. Install the seat cushion cover. 7. Zip the seat cover. 8. Install the seat cushion. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Kneeblocker - Removal Knee Diverter: Service and Repair Kneeblocker - Removal REMOVAL 1. Remove the steering column cover.See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 2. Remove mounting fasteners. 3. Remove knee bolster from instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Kneeblocker - Removal > Page 7628 Knee Diverter: Service and Repair Kneeblocker - Installation INSTALLATION 1. Place knee bolster into position. 2. Install the mounting fasteners. 3. Install the steering column cover. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7633 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way Air Bag Control Module: Diagrams Occupant Restraint Controller (Instrument Panel) 12 Way C2-A Connector - (INSTRUMENT PANEL) 12 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY C2-B Connector - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7636 MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7637 Air Bag Control Module: Diagrams Occupant Restraint Controller (Body) 36 Way C1-A Connector - (BODY) 36 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7638 C1-B Connector - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7639 MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7640 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7641 Air Bag Control Module: Diagrams Occupant Restraint Controller Module (Instrument Panel) 12 Way C2-A Connector - (INSTRUMENT PANEL) 12 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY C2-B Connector - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7642 MODULE-OCCUPANT RESTRAINT CONTROLLER - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7643 Air Bag Control Module: Diagrams Occupant Restraint Controller Module (Body) 36 Way C1-A Connector - (BODY) 36 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7644 C1-B Connector - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7645 MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 36 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller (Instrument Panel) 12 Way > Page 7646 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the base of the dash panel and just forward on the center instrument panel support in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, electronic impact sensors and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with five screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label (2) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has three integral mounting tabs and two integral locating pins. The molded plastic electrical connector (3), with two receptacles containing numerous terminal pins, exits the rearward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one from the body wire harness and one from the instrument panel wire harness. The impact sensors internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without side curtain airbags or seat (thorax) airbags, with or without third row seating as well as for those vehicles with domestic or export applications. These variations are necessary for both equipment needs and for compliance with certain regulatory requirements. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 7649 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness that is secured by a ground screw to the body sheet metal. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Various impact sensors within the ORC are continuously monitored by the ORC logic. These internal sensors, along with several external impact sensor inputs allow the ORC to determine both the severity of an impact and to verify the necessity for deployment of any airbags. Two remote front impact sensors are located on the back of the front end module carrier to the right and left of the cooling module near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The ORC also monitors inputs from an internal rollover sensor and up to six additional remote side impact sensors located on the left and right front door module carriers, on the right and left lower C-pillars and, on vehicles equipped with optional third row seating, on the right and left quarter inner panels to control deployment of the side curtain airbag units and seat (thorax) airbags. The impact sensors within the ORC are electronic accelerometer sensors that provide an additional logic input to the ORC microprocessor. These sensors are used to verify the need for a SRS component deployment by also detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. On vehicles equipped with side curtain airbags or seat airbags, a separate impact sensor within the ORC provides confirmation to the ORC microprocessor of side impact forces. This separate sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners, the seat airbags and either side curtain airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the mini console from the top of the floor panel transmission tunnel (3). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Removal. 3. First disconnect the instrument panel wire harness connector (4), followed by the body wire harness connector (5) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm to the fully open position on each connector. 4. Remove the three screws (1) that secure the ORC to the ORC bracket that is welded onto the top of the floor panel transmission tunnel. 5. Lift the ORC far enough to disengage the locating pins and remove the ORC from the bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 7652 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Carefully position the Occupant Restraint Controller (ORC) (2) to the ORC bracket that is welded onto the top of the floor panel transmission tunnel. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle and the locating pins on the bottom of the ORC will be engaged into the locating holes in the ORC bracket. 2. Install and tighten the three screws (1) that secure the ORC to the ORC bracket. Tighten the screws to 12.5 Nm (9 ft. lbs.). CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged. 3. First reconnect the body wire harness connector (5), followed by the instrument panel wire harness connector (4) to the ORC connector receptacles located on the rearward facing side of the module. Be certain that the latches on both connectors are each fully engaged. 4. Reinstall the mini console onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bin - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. NOTE: Service replacement ORC modules are shipped in a LOCKED OUT state and after installed will set a ORC UNLOCKED - ALL DEPLOYMENT DISABLED fault. Use a diagnostic scan tool to access the ORC module and go to the MISCELLANEOUS FUNCTIONS menu item to perform the MODULE INITIALIZATION procedure to erase the fault and initialize the new replacement ORC. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description Child Seat Tether Attachment: Description and Operation Child Seat Anchor - Description DESCRIPTION This vehicle is equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The LATCH system provides for the installation of suitable child restraints in certain seating positions without using the standard equipment seat belt provided for that seating position. The second row seats in this vehicle are equipped with three fixed-position child restraint upper tether anchors and five child restraint lower anchors. These anchorages allow for the installation of suitable child restraints to be installed in either both second row outboard seating positions or in just the second row center seating position. The second row upper tether anchors (1) are integral to the seat cushion frames (2). These anchors are each constructed from a heavy-gauge steel wire loop that is securely welded to the seat cushion frame. The second row child restraint upper tether anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with their respective second row seat cushion frame unit. The lower anchors (4) for this vehicle are also integral to their respective second row seat cushion frame. Sewn tags (2) with an embroidered child seat icon on the second row seat back trim cover (1) help identify the anchor locations because they may be otherwise difficult to see with the seat back in the upright position. These anchors are also constructed from a heavy-gauge steel wire loop that is securely welded to the seat cushion frame. They are each accessed from the front of the second row seat, where the seat back meets the seat cushion (3). These lower anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with the second row seat cushion frame unit. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description > Page 7659 Child Seat Tether Attachment: Description and Operation Child Seat Anchor - Operation OPERATION All vehicles manufactured for sale in the United States and Canada are required to be equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The second row seats in this vehicle has two pairs of anchor provisions for installing a LATCH-compatible child seat in each outboard seating position. Also, a single center anchor provision may be used in combination with the inboard anchor for either outboard seating position allowing a single seat to be mounted in the second row center seating position. With LATCH, child seats are secured by direct attachment to the vehicle seat structure, rather than by the seat belts. With LATCH-compatible child seats, lower anchors attach to the seat structure through heavy-gauge wire loops located at the intersection between the seat cushion and the seat back surfaces. Upper tether anchors are integral to the second row seat cushion frames to secure the top tether strap of child seats equipped with this feature. These upper tether anchors work with both LATCH-compatible and other child seats equipped with a top tether strap. The owner's information packet in the vehicle glove box contains details and suggestions on the proper use of all of the factory-installed child restraint anchors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair Seat Belt: Service and Repair WEB STOP BUTTON REPLACEMENT The webbing of the second row center seat belt tip half for this vehicle is equipped with a molded plastic web stop button, which holds the latch plate of the seat belt tip half in a readily accessible stored position and prevents it from falling to the lower belt anchor while the belt is not in use. If this button becomes damaged or separated from the belt webbing, it may be successfully replaced using the following procedure without the need for removing or replacing the entire seat belt assembly. The web stop button replacement kit includes two molded plastic replacement button halves: a male button half with a pointed spike in its center, and a female button half with a hole in its center. The button halves are not available separately. In addition to the button replacement kit, a pair of wheel weight pliers (such as KD Tools(R) #3358, Snap-on(R) #WWPR13A or equivalent) and a gel-type super adhesive glue (such as Mopar(R) Bond-All Gel #04467709 or equivalent) are required. NOTE: Avoid using heavy-duty, truck-style wheel weight pliers as the jaws may not close far enough to successfully complete web stop button replacement. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Carefully inspect the seat belt webbing to identify the hole or a witness mark where the original web stop button halves (2 and 5) were installed. If no distinct evidence of the prior button location is found, go to Step 2. If the original button location is clearly evident, go to Step 3. 2. Find the appropriate dimension in the Web Stop Button Location table. Measure and mark that distance (4) in the center of the belt webbing from the point where the webbing is secured to the seat belt lower anchor plate (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 7663 CAUTION: Be certain that the seat belt latch plate (1) is located and secured above the web stop button location mark before installing the replacement button. 3. Working from the side of the seat belt webbing that faces the interior of the vehicle, pierce the webbing with the spike in the center of the male button half. The male button head should face the interior of the vehicle. 4. Apply a small dot of gel-type super adhesive glue (2) around the center hole on the back side of the female button half (1). 5. Press the female button half over the spike of the male button half that protrudes through the side of the belt webbing that faces away from the interior of the vehicle. 6. Use the flat anvil-like jaw (3) of the wheel weight pliers to flatten the sharp spike (2) of the male button half that protrudes through the female button half (1) on the back side of the belt webbing (4). 7. Carefully use the curved jaw (3) of the wheel weight pliers to compress and form the flattened spike of the male button half (2) on the back side of the seat belt webbing (1) until it is concave and entirely below the outer convex surface of the female button half. 8. Check to be certain that the web stop button is secure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal Seat Belt Buckle: Service and Repair Seat Belt Buckle - Removal Front FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the front seat from the vehicle. See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Removal. 3. Remove the screw (3) that secures the front seat belt buckle (1) lower anchor to the bracket at the back of the inboard seat track. 4. Remove the buckle from the front seat. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7668 1. Move the second row right seat to the fully rearward position. 2. Move the second row left seat to the fully forward position. 3. Remove the plastic push-in fastener (3) that secures the outboard center seat back hinge bracket outboard trim (2) over the buckle (1) anchor to the left rear corner of the right seat frame. 4. Carefully pry the edges of the outboard center seat back hinge bracket outboard and inboard trim halves away from each other at their front and rear parting lines far enough to disengage the four integral latch features that secure the two halves of the trim to each other. 5. Carefully pry the outboard center seat back hinge bracket outboard trim away from the hinge bracket far enough to disengage the snap clip that secures the center of the trim to the bracket. 6. Remove the outboard trim from over the buckle anchor on the left rear corner of the right seat frame. 7. Remove the screw (2) that secures the buckle (1) lower anchor to the right seat frame. 8. Disengage the buckle from the elastic loop (3) of the right seat cushion trim cover and remove the buckle unit from the seat. Second Row - Left SECOND ROW - LEFT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7669 1. Move the second row left seat to the fully rearward position. 2. Move the second row right seat to the fully forward position. 3. Remove the screw (1) that secures the trim (2) over the buckle (3) anchor to the right rear corner of the left seat frame. 4. Remove the trim over the buckle anchor from the right rear corner of the left seat frame. 5. Remove the screw (1) that secures the buckle lower anchor (3) to the left seat frame. 6. Disengage the buckle from the elastic loop (2) of the left seat cushion trim cover and remove the buckle unit from the seat. Second Row - Right SECOND ROW - RIGHT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7670 1. Move the second row right seat to the fully forward position. 2. Reach under the rear edge of the second row right seat cushion frame just to the right of the lower end of the inboard center seat back hinge bracket (1) to access the right buckle lower anchor (3) and the center seat belt lower anchor (2). 3. Remove the screw (4) that secures the right buckle lower anchor and the center seat belt lower anchor to the right seat cushion frame. 4. From the front of the second row right seat, disengage the buckle (2) from the elastic loop (3) of the right seat cushion trim cover and pull the buckle lower anchor out from between the right seat cushion and back trim covers. Third Row THIRD ROW WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7671 1. Remove the third row seat cushion and cover from the rear floor panel (3) See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Reach between the two third row seat back hinge brackets on the rear floor panel to access and remove the screw (2) that secures the third row seat belt buckle (1) anchor plate to the rear floor. 3. Remove the two buckles from the rear floor panel as a unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7672 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Installation Front FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the front seat belt buckle (1) lower anchor to the bracket at the back of the inboard seat track. 2. Install and tighten the screw (3) that secures the lower anchor to the seat track bracket. Tighten the screw to 39 Nm (29 ft. lbs.). 3. Reinstall the front seat into the vehicle. See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Installation. 4. Reconnect the battery negative cable. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7673 1. Engage the second row center seat belt buckle (1) through the elastic loop (3) of the right seat cushion trim cover. 2. Position the buckle lower anchor to the left rear corner of the right seat frame. 3. Install and tighten the screw (2) that secures the buckle unit to the right seat frame. Tighten the screw to 39 Nm (29 ft. lbs.). 4. Position the outboard center seat back hinge bracket outboard trim (2) over the buckle (1) anchor on the left rear corner of the right seat frame. 5. Using hand pressure, align and press the outboard center seat back hinge bracket outboard trim toward the hinge bracket until the snap clip that secures the center of the trim snaps into the bracket. 6. Using hand pressure, squeeze the edges of the outboard center seat back hinge bracket outboard and inboard trim halves together until the four integral latch features that secure the two halves of the trim to each other are fully engaged. 7. Install the plastic push-in fastener (3) that secures the outboard center seat back hinge bracket outboard trim over the buckle anchor. 8. Restore the second row left seat to the fully rearward position. Second Row - Left SECOND ROW - LEFT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7674 1. Engage the second row left seat belt buckle through the elastic loop (2) of the left seat cushion trim cover. 2. Position the buckle lower anchor (3) to the right rear corner of the left seat frame. 3. Install and tighten the screw (1) that secures the buckle unit to the left seat frame. Tighten the screw to 39 Nm (29 ft. lbs.). 4. Position the trim (2) over the buckle (3) anchor on the right rear corner of the left seat frame. 5. Install and tighten the screw (1) that secures the trim over the buckle anchor. Tighten the screw securely. 6. Restore the second row right seat to the fully rearward position. Second Row - Right SECOND ROW - RIGHT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7675 1. From the front of the second row right seat, engage the second row right buckle (2) through the elastic loop (3) of the right seat cushion trim cover and insert the buckle lower anchor between the right seat cushion and back trim covers. 2. Reach under the rear edge of the second row right seat cushion frame just to the right of the lower end of the inboard center seat back hinge bracket (1) to position the buckle lower anchor (3) and the center seat belt lower anchor (2) to the right seat frame. 3. Install and tighten the screw (4) that secures the buckle unit and the center seat belt lower anchor to the right seat frame. Tighten the screw to 39 Nm (29 ft. lbs.). 4. Restore the second row right seat to the fully rearward position. Third Row THIRD ROW WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7676 1. Reach between the two third row seat back hinge brackets on the rear floor panel (3) to position the third row seat belt buckle (1) anchor plate to the rear floor. 2. Install and tighten the screw (2) that secures the anchor plate to the rear floor panel. Tighten the screw to 90 Nm (66 ft. lbs.). 3. Reinstall the third row seat cushion and cover onto the rear floor panel (3) See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7680 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7681 Seat Belt Buckle Switch: Diagrams Connector - (BODY) 2 WAY SWITCH-SEAT BELT-DRIVER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the seat belt retractor frame (2) over the retractor spool (1) for the driver side front seat. The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description > Page 7684 Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Operation OPERATION The driver side front seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Totally Integrated Power Module (TIPM). The TIPM provides electronic driver side seat belt switch status messages to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC controls the seat belt indicator based upon the electronic driver side seat belt switch status message inputs. The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The seat belt switch is connected in series between ground and the seat belt switch sense input of the TIPM. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The TIPM monitors the condition of the driver seat belt switch circuits and will send an electronic message to illuminate the airbag indicator in the EMIC then store a Diagnostic Trouble Code (DTC) for any fault that is detected. The hard wired circuits between the driver side seat belt switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the switch or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the driver side seat belt switch or the electronic controls and communication related to seat belt switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster - Removal Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster - Removal REMOVAL WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Remove the upper trim (4) from the B-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 3. Remove the screw that secures the seat belt turning loop (5) to the height adjuster (3) on the upper B-pillar. 4. Remove the seat belt turning loop from the height adjuster. 5. Remove the screw (2) that secures the top of the height adjuster to the B-pillar. 6. Disengage the tabs at the bottom of the height adjuster from the slots in the B-pillar. 7. Remove the adjuster from the B-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster - Removal > Page 7689 Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster - Installation INSTALLATION WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the seat belt turning loop height adjuster (3) to the upper inner B-pillar (1). 2. Engage the tabs at the bottom of the height adjuster into the slots in the B-pillar. 3. Install and tighten the screw (2) that secures the height adjuster to the B-pillar. Tighten the screw to 58 Nm (43 ft. lbs.). 4. Position the seat belt turning loop onto the height adjuster on the upper B-pillar. Be certain the seat belt webbing is not twisted between the turning loop and the web guide or between the turning loop and the lower anchor. 5. Install and tighten the screw (2) that secures the turning loop to the height adjuster. Tighten the screw to 37 Nm (27 ft. lbs.). 6. Reinstall the upper trim (4) onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster - Removal > Page 7690 Seat Belt Height Adjuster: Service and Repair Seat Belt Retractor - Removal THIRD ROW TURNING LOOP BRACKET WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Unsnap and remove the trim cover (1) from the third row seat belt turning loop on the inside of the upper D-pillar trim (3) to access the turning loop screw (2). 2. Remove the screw (2) that secures the seat belt turning loop to the bracket on the inside of the upper D-pillar. 3. Remove the turning loop from the D-pillar. 4. Remove the trim from the inside of the upper D-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 5. Remove the two screws (2) that secure the seat belt turning loop bracket (1) to the inside of the upper D-pillar (3). 6. Remove the turning loop bracket from the D-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster - Removal > Page 7691 Seat Belt Height Adjuster: Service and Repair Seat Belt Retractor - Installation THIRD ROW TURNING LOOP BRACKET WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the third row turning loop bracket (1) to the inside of the upper D-pillar (3). 2. Install and tighten the two screws (2) that secure the turning loop bracket to the D-pillar. Tighten the screws to 22 Nm (16 ft. lbs.). 3. Reinstall the trim (3) onto the inside of the upper D-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 4. Position the seat belt turning loop to the inside of the upper D-pillar. Be certain the seat belt webbing (5) is not twisted between the retractor and the turning loop as well as between the turning loop and the lower anchor. 5. Install and tighten the screw (2) that secures the turning loop to the bracket on the inside of the upper D-pillar. Tighten the screw to 43 Nm (32 ft. lbs.). 6. Snap the trim cover (1) over the seat belt turning loop on the inside of the upper D-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Seat Belt Retractor - Description Seat Belt Retractor: Description and Operation Seat Belt Retractor - Description DESCRIPTION The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism as standard equipment. However, the retractor locking mechanism for all seating positions except the driver side front and the second row center are mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in these seating positions of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the seat belt retractor unit and is concealed beneath a molded plastic cover located on the side of the retractor spool. The automatic locking mechanism cannot be adjusted or repaired and, if ineffective or damaged, the entire seat belt and retractor unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Seat Belt Retractor - Description > Page 7696 Seat Belt Retractor: Description and Operation Seat Belt Retractor - Operation OPERATION The locked mode of the retractor is engaged and the automatic locking retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make an audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal Seat Belt Retractor: Service and Repair Seat Belt Retractor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Adjust the front seat to its most forward position for easiest access to the front seat belt lower anchor and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the seat belt anchor cover (3) to remove it from the rear of the outboard front seat (2) side shield. 4. Remove the screw (4) that secures the front seat belt (1) lower anchor to the bracket on the outboard side of the front seat cushion frame. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7699 5. Remove the lower and upper trim (4) from the B-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 6. Remove the screw (3) that secures the seat belt (5) turning loop to the height adjuster (2) on the upper B-pillar. 7. Using a trim stick or another suitable wide flat-bladed tool, gently pry the seat belt web guide (6) to unsnap it from the B-pillar. 8. Disconnect the body wire harness connector (1) from the seat belt tensioner initiator on the retractor (3). 9. On the driver side only, disconnect the second body wire harness connector from the seat belt switch connector receptacle on the retractor. 10. Remove the screw (4) that secures the lower retractor bracket to the inner B-pillar (2). 11. Remove the front seat belt and retractor from the B-pillar as a unit. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7700 1. Remove the second row right seat from the vehicle. See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Removal. 2. Reach under the rear edge of the second row right seat cushion frame just to the right of the lower end of the inboard center seat back hinge bracket (1) to access the right buckle lower anchor (3) and the center seat belt lower anchor (2). 3. Remove the screw (4) that secures the right buckle lower anchor and the center seat belt lower anchor to the right seat cushion frame. 4. From the front of the second row right seat, pull the center seat belt lower anchor out from between the right seat cushion and back trim covers. 5. Using a trim stick or another suitable wide flat-bladed tool, carefully pry the belt web guide bezel (3) upward from the top of the right seat back (2) far enough to disengage the three barrel clips that secure the bezel to the seat back frame. 6. Slide the center seat belt webbing (1) through the slot in the guide bezel to disengage the belt from the bezel. 7. Remove the head rest, back panel and trim cover from the right seat back frame (1). It is not necessary to remove the seat back frame from the seat cushion frame. See: Body and Frame/Seats/Seat Back/Service and Repair/Seat Back - Removal. 8. Remove the screws (4) that secure the molded plastic shield (5) to the top of the seat back frame. Pull the top of the seat back foam away from the seat back frame to access the lower screws securing the shield. 9. Remove the molded plastic shield from the top of the seat back frame. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7701 10. From the back side of the seat back frame, remove the screw (2) that secures the retractor (3) to the frame. 11. Lift the retractor upward far enough to disengage the T-tab of the retractor bracket from the keyed slot in the seat back frame. 12. Guide the seat belt webbing through the slot in the top of the seat back frame while removing the seat belt and retractor from the seat as a unit. Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Loosen the front of the quarter trim panel from the lower C-pillar (1) enough to access the second row outboard seat belt and retractor. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 2. Remove the screw (4) that secures the second row outboard seat belt (2) lower anchor to the rear floor panel (3) near the base of the C-pillar. 3. Remove the upper trim (6) from the inside of the C-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (1) that secures the seat belt turning loop to the inside of the upper C-pillar (3). 5. Remove the seat belt turning loop from the C-pillar. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the seat belt web guide (2) to unsnap it from the quarter inner panel near the base of the C-pillar. 7. Remove the screw (4) that secures the retractor (5) bracket to the quarter inner panel. 8. Lift the retractor upward far enough to disengage the retractor tab from the keyed hole in the quarter inner panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7702 9. Remove the second row outboard seat belt and retractor from the vehicle as a unit. Third Row Seat Belt and Retractor THIRD ROW SEAT BELT AND RETRACTOR WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the third row seat cushion and cover from the rear floor panel See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Remove the screw (2) that secures the third row seat belt lower anchor (1) and the third row seat back (3) outboard bracket to the rear floor panel. 3. Remove the lower anchor from the third row seat back outboard bracket. 4. Unsnap and remove the trim cover (1) from the third row seat belt turning loop on the inside of the upper D-pillar trim (3) to access the turning loop screw (2). 5. Remove the screw (2) that secures the seat belt turning loop to the bracket on the inside of the upper D-pillar. 6. Remove the turning loop from the D-pillar. 7. Remove the trim from the inside of the upper D-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 8. Loosen the rear of the quarter trim panel from the lower D-pillar enough to access the third row outboard seat belt and retractor (7) See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 9. Remove the screw (4) that secures the upper retractor bracket to the inside of the D-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7703 10. Remove the screw (6) that secures the lower retractor bracket to the inside of the D-pillar. 11. Lift the retractor upward far enough to disengage the tab of the upper retractor bracket from the keyed hole in the D-pillar. 12. Remove the third row seat belt and retractor from the vehicle as a unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7704 Seat Belt Retractor: Service and Repair Seat Belt Retractor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Position the front seat belt and retractor (3) to the inner B-pillar (2) as a unit. 2. On the driver side only, reconnect the body wire harness connector to the seat belt switch connector receptacle on the retractor. 3. Reconnect the body wire harness connector (1) to the seat belt tensioner initiator on the retractor. 4. Install and tighten the screw (4) that secures the lower retractor bracket to the inner B-pillar. Tighten the screw to 58 Nm (43 ft. lbs.). 5. Be certain to route the wiring for the seat belt tensioner behind the B-pillar flange to ensure it does not interfere with the seat belt webbing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7705 6. Position the web guide (6) to the B-pillar (1). Be certain the seat belt webbing (5) is not twisted between the retractor and the web guide. 7. Using hand pressure, press firmly and evenly on the web guide to snap it into place. 8. Position the seat belt turning loop onto the height adjuster (2) on the upper B-pillar. Be certain the seat belt webbing is not twisted between the web guide and the turning loop. 9. Install and tighten the screw (3) that secures the turning loop to the height adjuster. Tighten the screw to 37 Nm (27 ft. lbs.). 10. Reinstall the upper (4) and lower trim onto the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 11. Position the front seat belt (1) lower anchor to the bracket on the outboard side of the front seat (2) cushion frame. Be certain the seat belt webbing is not twisted between the turning loop and the lower anchor. 12. Install and tighten the screw (4) that secures the lower anchor to the bracket on the outboard side of the front seat cushion frame. Tighten the screw to 51 Nm (38 ft. lbs.). 13. Align the seat belt anchor cover (3) to the opening near the rear of the outboard seat side shield. Using hand pressure, press firmly and evenly on the cover until it snaps into place. 14. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7706 1. Guide the seat belt webbing through the slot in the top of the right seat back frame (1) while positioning the center seat belt and retractor (3) to the frame as a unit. Be certain the seat belt webbing is not twisted between the retractor and the top of the seat. 2. Engage the T-tab of the retractor bracket with the keyed slot in the seat back frame. 3. From the back side of the seat back frame, install and tighten the screw (2) that secures the retractor to the frame. Tighten the screw to 39 Nm (29 ft. lbs.). 4. Position the molded plastic shield (5) onto the top of the seat back frame. 5. Install and tighten the screws (4) that secure the molded plastic shield to the top of the seat back frame. Pull the top of the seat back foam away from the seat back frame to access the lower screws securing the shield. 6. Reinstall the trim cover, back panel and head rest to the right seat back frame. See: Body and Frame/Seats/Seat Back/Service and Repair/Seat Back - Installation. 7. Grasp the center seat belt webbing (1) between where it exits the top of the seat and the seat belt latch plate and slide it through the slot in the belt web guide bezel (3) to engage the belt through the bezel. 8. Position the guide bezel to the top of the right seat back (2) with the slot facing forward. 9. Using hand pressure, press the guide bezel down onto the top of the right seat back far enough to engage the three barrel clips that secure the bezel to the seat back frame. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7707 10. From the front of the second row right seat, insert the center seat belt lower anchor between the right seat cushion and back trim covers. Be certain the seat belt webbing is not twisted between the top of the seat and the belt lower anchor. 11. Reach under the rear edge of the second row right seat cushion frame just to the right of the lower end of the inboard center seat back hinge bracket (1) to position the buckle lower anchor (3) and the center seat belt lower anchor (2) to the right seat frame. 12. Install and tighten the screw (4) that secures the buckle unit and the center seat belt lower anchor to the right seat frame. Tighten the screw to 39 Nm (29 ft. lbs.). 13. Reinstall the second row right seat into the vehicle. See: Body and Frame/Seats/Service and Repair/Seats, Front/Seat - Installation. Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the second row outboard seat belt and retractor (5) to the quarter inner panel just below the base of the upper C-pillar (3) as a unit. 2. Engage the tab on the retractor bracket into the keyed hole in the quarter inner panel. 3. Install and tighten the screw (4) that secures the retractor to the quarter inner panel. Tighten the screw to 58 Nm (43 ft. lbs.). 4. Position the web guide (2) to the quarter inner panel near the base of the C-pillar. Be certain the seat belt webbing is not twisted between the retractor and the web guide. 5. Using hand pressure, press firmly and evenly on the web guide to snap it into place. 6. Position the seat belt turning loop to the inside of the upper C-pillar. Be certain the seat belt webbing is not twisted between the web guide and the turning loop. 7. Install and tighten the screw (1) that secures the turning loop to the C-pillar. Tighten the screw to 43 Nm (32 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7708 8. Reinstall the upper trim (2) onto the inside of the C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 9. Position the lower seat belt (2) anchor to the rear floor panel (3) near the base of the lower C-pillar (1). Be certain the seat belt webbing is not twisted between the turning loop and the lower anchor. 10. Install and tighten the screw (4) that secures the lower seat belt anchor to the floor. Tighten the screw to 58 Nm (43 ft. lbs.). 11. Reinstall the front of the quarter trim panel onto the lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. Third Row Seat Belt and Retractor THIRD ROW SEAT BELT AND RETRACTOR WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the third row seat belt and retractor (7) to the inside of the D-pillar (5) as a unit. 2. Engage the tab of the upper retractor bracket into the keyed hole in the D-pillar. 3. Install and tighten the screw (6) that secures the lower retractor bracket to the inside of the D-pillar. Tighten the screw to 58 Nm (43 ft. lbs.). 4. Install and tighten the screw (4) that secures the upper retractor bracket to the inside of the D-pillar. Tighten the screw to 10 Nm (7 ft. lbs.). 5. Reinstall the rear of the quarter trim panel to the lower D-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Reinstall the trim (3) onto the inside of the upper D-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7709 Trim/D-Pillar Trim/Installation. 7. Position the seat belt turning loop to the inside of the upper D-pillar. Be certain the seat belt webbing (5) is not twisted between the retractor and the turning loop. 8. Install and tighten the screw (2) that secures the turning loop to the bracket on the inside of the upper D-pillar. Tighten the screw to 43 Nm (32 ft. lbs.). 9. Snap the trim cover (1) over the seat belt turning loop on the inside of the upper D-pillar. 10. Position the seat belt lower anchor (1) to the third row seat back (3) outboard bracket on the rear floor panel. Be certain the seat belt webbing is not twisted between the turning loop and the lower anchor. 11. Install and tighten the screw (2) that secures the lower anchor and the third row seat back outboard bracket to the rear floor panel. Tighten the screw to 90 Nm (66 ft. lbs.). 12. Reinstall the third row seat cushion and cover to the rear floor panel See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Driver Seat Belt Tensioner Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Driver Seat Belt Tensioner > Page 7714 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Belt Tensioner (Body) 2 Way Seat Belt Tensioner: Diagrams Driver Seat Belt Tensioner (Body) 2 Way Connector - (BODY) 2 WAY SEAT BELT-TENSIONER-DRIVER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Belt Tensioner (Body) 2 Way > Page 7717 Seat Belt Tensioner: Diagrams Passenger Seat Belt Tensioner (Body) 2 Way Connector - (BODY) 2 WAY SEAT BELT-TENSIONER-PASSENGER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tensioner - Description Seat Belt Tensioner: Description and Operation Seat Belt Tensioner - Description DESCRIPTION The seat belt tensioners are integral to the front seat belt retractor units (4), which are secured to the inner B-pillar on the right and left sides of the vehicle. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube (3), a cast metal housing, numerous steel balls, a stamped metal ball trap (2), a torsion bar and a small pyrotechnically activated gas generator with a connector receptacle (1). All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching yellow molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. See: Seat Belt Retractor/Service and Repair/Seat Belt Retractor Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tensioner - Description > Page 7720 Seat Belt Tensioner: Description and Operation Seat Belt Tensioner - Operation OPERATION The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. They may also be deployed in certain vehicle rollover events in conjunction with the side curtain airbags and the seat (thorax) airbags. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of harmful contact with the steering wheel, steering column, instrument panel or windshield. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. Proper diagnosis of the seat belt tensioner gas generator and the seat belt tensioner squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor > Page 7725 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Seat) 2 Way Seat Sensor/Switch: Diagrams Driver Seat Track Position Sensor (Seat) 2 Way Connector - (SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Seat) 2 Way > Page 7728 Seat Sensor/Switch: Diagrams Passenger Seat Track Position Sensor (Seat) 2 Way Connector - (SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-PASSENGER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7734 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7735 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7736 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7737 Impact Sensor: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7738 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7739 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7740 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7741 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7742 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7743 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7744 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way Impact Sensor: Diagrams Left Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-LEFT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7747 Impact Sensor: Diagrams Right Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7748 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-LEFT 1 - (FRONT DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7749 Impact Sensor: Diagrams Left Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7750 Impact Sensor: Diagrams Left Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-LEFT - (FRONT END MODULE) 2 WAY Right Front Impact Sensor (Front End Module) 2 Way Connector - (FRONT END MODULE) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7751 Left Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-LEFT 1 - (FRONT DOOR) 3 WAY Left Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7752 Right Side Impact Sensor 1 (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (FRONT DOOR) 3 WAY Right Side Impact Sensor 3 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-RIGHT 3 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7753 Left Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 2 WAY Right Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Front End Module) 2 Way > Page 7754 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Vehicle Front VEHICLE FRONT Two acceleration-type front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the back of the front end module carrier on either outboard side of the cooling module, just inboard of each front lamp unit housing within the engine compartment. The sensor housing has an integral connector receptacle (3), an integral locating and anti-rotation pin, and an integral mounting hole (2). The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the front end module wire harness. These acceleration-type front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Front Door SIDE - FRONT DOOR Two pressure-type front door side impact sensors (2) are used on this vehicle when it is equipped with the side curtain airbags or the optional seat (also known as thorax) airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with two screws and is sealed by a resilient gasket (1) to the front door module carrier on the inside of the front door. The sensors are concealed behind the front door trim panel within the passenger compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7757 The right and left front door side impact sensors are identical in construction and calibration. The impact sensor housing has an integral connector receptacle (3), two integral mounting tabs, and an integral hood-like water shield (4) that extends through a hole in the front door module carrier into the interior of the door cavity and protects the sensor orifice from contamination. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor, which includes an electronic communication chip and the pressure sensor. The housing cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. A label on the sensor has a directional arrow and the word down imprinted upon it to provide verification of the correct sensor orientation in the vehicle. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the front door wire harness. These pressure-type front door side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Second Row Seating SIDE - SECOND ROW SEATING Two acceleration-type second row seating side impact sensors (1) are used on this vehicle when it is equipped with the side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the lower C-pillar just above the rear door opening sill within the passenger compartment. The sensor housing has an integral connector receptacle (3), an integral locating anti-rotation pin, and an integral mounting hole (2). The right and left second row seating side impact sensors are identical in construction and calibration. However, the connector orientation in the vehicle is reversed. The connector receptacle faces forward on the right side of the vehicle, and faces rearward on the left side of the vehicle. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The second row seating side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. These acceleration-type second row seating side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side - Third Row Seating SIDE - THIRD ROW SEATING Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7758 Two acceleration-type third row seating side impact sensors (1) are used on this vehicle when it is equipped with the side curtain airbags and seven-passenger seating, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left quarter inner panel just above the right or left rear wheel housing within the passenger compartment. The sensor housing has an integral connector receptacle (3), an integral locating anti-rotation pin, and an integral mounting hole (2). The right and left third row seating side impact sensors are identical in construction and calibration. However, the connector orientation in the vehicle is reversed. The connector receptacle faces forward on the right side of the vehicle, and faces rearward on the left side of the vehicle. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. The cavity is filled with a potting material to seal and protect the internal electronic circuitry and components. The third row seating side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. These acceleration-type third row seating side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7759 Impact Sensor: Description and Operation Impact Sensor - Operation Vehicle Front VEHICLE FRONT The acceleration-type front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the front passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and commands the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the sensor plus circuit. The hard wired circuits between the acceleration-type front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Front Door SIDE - FRONT DOOR The pressure-type front door side impact sensors recognize a side impact in the front door area by monitoring changes in pressure within the front door cavity, which manifests itself as a sudden pressure wave as the door collapses during an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the sensor plus circuit. The hard wired circuits between the pressure-type front door side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the pressure-type front door side impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Second Row Seating SIDE - SECOND ROW SEATING The acceleration-type second row seating side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the acceleration-type second row seating side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type second row seating side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side - Third Row Seating Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7760 SIDE - THIRD ROW SEATING The acceleration-type third row seating side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the acceleration-type third row seating side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to acceleration-type third row seating side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Vehicle Front VEHICLE FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Service access for the front impact sensors is accomplished by reaching behind the front end module carrier (2) from the top of the engine compartment and between the inboard end of either front lamp unit housing (3) and either outboard end of the cooling module. 3. For the left front impact sensor only, remove the fresh air intake snorkel and the air filter housing from behind the front end module carrier for service access. 4. Disconnect the front end module wire harness connector (5) from the connector receptacle of the right or left front impact sensor (1). 5. Remove the screw (4) that secures the front impact sensor to the back (engine compartment side) of the front end module carrier. 6. Pull the front impact sensor straight back from the mounting location to disengage the anti-rotation pin on the base of the sensor from the clearance hole in the front end module carrier. 7. Remove the right or left front impact sensor from the engine compartment. Side - Front Door SIDE - FRONT DOOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7763 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the trim panel from the inside of the right or left front door. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the front door wire harness connector (3) from the side impact sensor (1) connector receptacle. 4. Remove the two screws (2) that secure the side impact sensor to the front door module carrier panel (4). 5. Remove the side impact sensor from the door. Side - Second Row Seating SIDE - SECOND ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Open the sliding door. 3. Remove the quarter trim panel from the lower C-pillar (1).See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 4. Disconnect the body wire harness connector (4) from the side impact sensor (3) connector receptacle. 5. Remove the screw (2) that secures the side impact sensor to the lower C-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7764 6. Pull the side impact sensor straight out from the mounting location to unsnap the anti-rotation pin on the base of the sensor from the clearance hole in the lower C-pillar. 7. Remove the side impact sensor from the vehicle. Side - Third Row Seating SIDE - THIRD ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the quarter trim panel from the quarter inner panel over the rear wheel housing (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the body wire harness connector (2) from the side impact sensor (4) above the rear wheel housing on the quarter inner panel. 4. Remove the screw (3) that secures the side impact sensor to the quarter inner panel. 5. Pull the side impact sensor straight out from the mounting location to disengage the anti-rotation pin on the base of the sensor from the clearance hole in the quarter inner panel. 6. Remove the side impact sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7765 Impact Sensor: Service and Repair Impact Sensor - Installation Vehicle Front VEHICLE FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Service access for the front impact sensors is accomplished by reaching behind the front end module carrier (2) from the top of the engine compartment and between the inboard end of either front lamp unit housing (3) and either outboard end of the cooling module. 2. Position the right or left front impact sensor (1) into the engine compartment. 3. Align and insert the anti-rotation pin on the base of the sensor into the clearance hole on the back (engine compartment side) of the front end module carrier. 4. Install and tighten the screw (4) that secures the front impact sensor to the front end module carrier. Tighten the screw to 11 Nm (97 in. lbs.). 5. Reconnect the front end module wire harness connector (5) to the connector receptacle of the front impact sensor. 6. For the left front impact sensor only, reinstall the fresh air intake snorkel and the air filter housing behind the front end module carrier. 7. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - Front Door SIDE - FRONT DOOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7766 NOTE: Be certain that the gasket between the pressure-type side impact sensor and the front door module carrier panel is in good condition and positioned on the back of the sensor. There MUST be a good seal between the sensor and the module carrier panel for the sensor to operate properly. If the gasket is in poor condition, replace the sensor. 1. Position the side impact sensor (1) to the right or left front door module carrier panel (4). When the sensor is correctly positioned, the arrow on the sensor label will be pointed toward the bottom of the door. 2. Install and tighten the two screws (2) that secure the side impact sensor to the door. Tighten the screws to 2.4 Nm (21 in. lbs.). 3. Reconnect the front door wire harness connector (3) to the sensor connector receptacle. 4. Reinstall the trim panel onto the inside of the right or left front door. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - Second Row Seating SIDE - SECOND ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7767 1. Position the side impact sensor (3) to the lower C-pillar (1). 2. Align the anti-rotation pin on the base of the sensor with the clearance hole in the lower C-pillar, then press on the sensor firmly and evenly to snap the pin into place. 3. Install and tighten the screw (2) that secures the side impact sensor to the lower C-pillar. Tighten the screw to 11 Nm (97 in. lbs.). 4. Reconnect the body wire harness connector (4) to the side impact sensor on the lower C-pillar. 5. Reinstall the quarter trim panel onto the lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - Third Row Seating SIDE - THIRD ROW SEATING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and the second or third row seating side impact sensors are interchangeable. 1. Position the side impact sensor (4) to the quarter inner panel above the rear wheel housing (1). 2. Align the anti-rotation pin on the base of the sensor with the clearance hole in the quarter inner panel, then press on the sensor firmly and evenly to snap the pin into place. 3. Install and tighten the screw (3) that secures the side impact sensor to the quarter inner panel. Tighten the screw to 11 Nm (97 in. lbs.). 4. Reconnect the body wire harness connector (2) to the side impact sensor on the quarter inner panel. 5. Reinstall the quarter trim panel onto the quarter inner panel over the rear wheel housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7771 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7772 Seat Belt Buckle Switch: Diagrams Connector - (BODY) 2 WAY SWITCH-SEAT BELT-DRIVER - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the seat belt retractor frame (2) over the retractor spool (1) for the driver side front seat. The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description > Page 7775 Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Operation OPERATION The driver side front seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Totally Integrated Power Module (TIPM). The TIPM provides electronic driver side seat belt switch status messages to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC controls the seat belt indicator based upon the electronic driver side seat belt switch status message inputs. The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The seat belt switch is connected in series between ground and the seat belt switch sense input of the TIPM. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The TIPM monitors the condition of the driver seat belt switch circuits and will send an electronic message to illuminate the airbag indicator in the EMIC then store a Diagnostic Trouble Code (DTC) for any fault that is detected. The hard wired circuits between the driver side seat belt switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the switch or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the driver side seat belt switch or the electronic controls and communication related to seat belt switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver side front seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 7780 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC sends messages over the CAN data bus to control the illumination of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the rear edge of the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 7783 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the rear edge of the front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the blade of the sensor bracket (1) located on the inboard side near the rear of the upper inboard seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor > Page 7788 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Seat) 2 Way Seat Sensor/Switch: Diagrams Driver Seat Track Position Sensor (Seat) 2 Way Connector - (SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Seat) 2 Way > Page 7791 Seat Sensor/Switch: Diagrams Passenger Seat Track Position Sensor (Seat) 2 Way Connector - (SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-PASSENGER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Locations > Page 7797 Antenna, Navigation: Diagrams Connector (COMPONENT SIDE) - (GPS ANTENNA) 2 WAY ANTENNA-NAVIGATION (COMPONENT SIDE) - (GPS ANTENNA) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Navigation Antenna - Removal Antenna, Phone: Service and Repair Navigation Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the radio. See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 4. Remove the defroster grille. See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 5. Remove the GPS antenna mounting fasteners and remove the antenna. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair > Navigation Antenna - Removal > Page 7802 Antenna, Phone: Service and Repair Navigation Antenna - Installation INSTALLATION 1. Install the GPS antenna and mounting fasteners. 2. Install the defroster grille. See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Installation. 3. Install the radio. See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 4. Install the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Diagrams > Satellite Video Antenna 1 (Body) 2 Way Antenna, TV: Diagrams Satellite Video Antenna 1 (Body) 2 Way Connector - (BODY) 2 WAY ANTENNA-SATELLITE VIDEO 1 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Diagrams > Satellite Video Antenna 1 (Body) 2 Way > Page 7808 Antenna, TV: Diagrams Satellite Video Antenna 2 (Body) 2 Way Connector - (BODY) 2 WAY ANTENNA-SATELLITE VIDEO 2 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Description and Operation > Satellite Video Antenna - Description Antenna, TV: Description and Operation Satellite Video Antenna - Description DESCRIPTION The satellite video antenna cable connects the roof mounted antenna to the satellite receiver. It has two connectors at each end and is routed above the headliner, then down the right side A-pillar to the cowl area. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Description and Operation > Satellite Video Antenna - Description > Page 7811 Antenna, TV: Description and Operation Satellite Video Antenna - Operation OPERATION The satellite video antenna receives signals from orbiting satellites and sends these signals to the satellite receiver module. The satellite video antenna must have open space in which to operate. Items carried on the roof, parking inside etc. can have an effect on the antenna's ability to receive signals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna - Removal Antenna, TV: Service and Repair Satellite Video Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the appropriate portion of the headliner as necessary, to access the underside of the antenna. 3. Disconnect the electrical connectors from the antenna. 4. Remove the fastener and retainer. 5. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna - Removal > Page 7814 Antenna, TV: Service and Repair Satellite Video Antenna - Installation INSTALLATION 1. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. 2. Connect the electrical connector to the antenna. 3. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 4. Connect battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description Keyless Start Antenna: Description and Operation Remote Start Antenna - Description DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the Wireless Ignition Node (WIN) (1), a length of coaxial cable (2), two mounting clips (3 and 4) and a control module/antenna (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description > Page 7819 Keyless Start Antenna: Description and Operation Remote Start Antenna - Operation OPERATION The remote start antenna is an external hidden antenna located at the driver's side front of dash. The antenna interfaces with the Wireless Integration Node (WIN) through a coaxial electrical cable and electrical connector. The antenna helps to amplify the signal for the Remote Keyless Entry (RKE) key fob. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. Failure to do this may result in serious or fatal injury. The remote start antenna is located driver's side front of dash. 1. Disconnect and isolate the battery negative cable. 2. Remove radio. Refer to See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 3. Remove instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 4. Remove the instrument panel top pad. Refer to See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. NOTE: During removal of the remote start antenna note the routing location of the coaxial cable. 5. Disconnect remote start antenna coaxial cable connector (1) from skreem module (3). 6. Remove the mounting clip (2). 7. Remove the mounting clip at the steering column reinforcement bracket. 8. Remove screws (1) and remove remote start antenna (2) from instrument panel assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 7822 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION NOTE: Make sure the remote start antenna is positioned the same way noted during the removal procedure. 1. Install the remote start antenna (2) and screws (1) to instrument panel assembly. Tighten to 2.5 Nm (22 in. lbs.). 2. Route the remote start coaxial cable in the position noted during the removal procedure. 3. Install the coaxial cable mounting clip at the steering column reinforcement bracket. 4. Install the mounting clip (2). 5. Connect remote start antenna coaxial cable connector (1) to skreem module (3). 6. Install instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install radio. Refer to See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 8. Install the instrument panel top pad. Refer to See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. 9. Connect negative battery cable. Tighten to 5 Nm (45 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna Antenna, Radio: Locations Radio Antenna Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna > Page 7827 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna > Page 7828 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna > Page 7829 Antenna, Radio: Locations Radio Antenna (Satellite Radio) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna > Page 7830 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna > Page 7831 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Diagrams > Radio Antenna C1 (Headliner) 2 Way Antenna, Radio: Diagrams Radio Antenna C1 (Headliner) 2 Way Connector C1 - (HEADLINER) 2 WAY ANTENNA-RADIO - (HEADLINER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Diagrams > Radio Antenna C1 (Headliner) 2 Way > Page 7834 Antenna, Radio: Diagrams Radio Antenna C2 (Headliner) 1 Way Connector C2 - (HEADLINER) 1 WAY ANTENNA-RADIO - (HEADLINER) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Diagrams > Radio Antenna C1 (Headliner) 2 Way > Page 7835 Antenna, Radio: Diagrams Radio Antenna C3 (Satellite Radio) (Body) 2 Way Connector C3 (SATELLITE RADIO) - (BODY) 2 WAY ANTENNA-RADIO (SATELLITE RADIO) - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal Antenna, Radio: Service and Repair Satellite Radio Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the appropriate portion of the headliner as necessary to access the underside of the antenna See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the antenna electrical connectors. 4. Remove the fastener and retainer. 5. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 7838 Antenna, Radio: Service and Repair Satellite Radio Antenna - Installation INSTALLATION 1. Insert the antenna electrical connector through the hole in the roof panel. 2. Press the antenna into position until both retainers snap into place. Tighten to 9 Nm (80 in. lbs.). 3. Connect the antenna electrical connector to the antenna. 4. Install headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 5. Connect negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 7839 Antenna, Radio: Service and Repair Antenna - Removal REMOVAL NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. SATELLITE AUDIO ONLY 1. Disconnect and isolate the battery negative cable 2. Lower the rear portion of the headliner as necessary to gain access to the audio antenna See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the antenna cable(s). 4. Remove antenna mast by unscrewing mast from antenna body. 5. Remove the fastener from the mounting bracket. 6. Remove the antenna bracket. 7. Remove the antenna base from the roof of the vehicle. 8. Remove the passenger side quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 9. Remove the passenger side C-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal. 10. Remove the passenger side scuff plates See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Removal. 11. Remove the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Removal . 12. Remove the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 13. Remove the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 14. Disconnect the antenna. SATELLITE AUDIO AND VIDEO AUDIO CABLE TO MODULE NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Disconnect and isolate the battery negative cable. 2. Lower the rear portion of the headliner as necessary to gain access to the audio antenna See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the antenna cable(s). 4. Remove antenna mast by unscrewing mast from antenna body. 5. Remove the fastener from the mounting bracket. 6. Remove the antenna bracket. 7. Remove the antenna base from the roof of the vehicle. 8. Remove the passenger side quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 9. Remove the passenger side C-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal 10. Remove the passenger side scuff plates See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Removal. 11. Position the passenger seat forward. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 12. Disconnect the audio antenna from the module. VIDEO CABLE TO MODULE NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Disconnect and isolate the battery negative cable. 2. Lower the front portion of the headliner as necessary to gain access to the video antenna See: Body and Frame/Interior Moulding / Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 7840 Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the antenna cable(s). 4. Remove antenna mast by unscrewing mast from antenna body. 5. Remove the fastener from the mounting bracket. 6. Remove the antenna bracket. 7. Remove the antenna base from the roof of the vehicle. 8. Remove the passenger side front scuff plate See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate Removal. 9. Remove the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel - Removal . 10. Position the passenger seat forward. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 11. Disconnect the video antenna from the module. SIGNAL (RADIO FEED) ANTENNA CABLE FROM MODULE TO COWL NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Disconnect and isolate the battery negative cable. 2. Remove the passenger side front scuff plate See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate Removal. 3. Remove the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel - Removal . 4. Position the passenger seat forward. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 5. Disconnect the signal (radio feed) antenna from the module. 6. Disconnect the antenna cable from the instrument panel antenna cable in the cowl area. SIGNAL (RADIO FEED) ANTENNA FROM COWL TO RADIO NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Disconnect and isolate the battery negative cable. 2. Remove the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Removal . 3. Remove the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 4. Remove the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 5. Disconnect the antenna from the radio. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 7841 Antenna, Radio: Service and Repair Antenna - Installation INSTALLATION SATELLITE AUDIO ONLY NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Route the cable behind the glove box, up to the radio and secure. 2. Connect the antenna to the radio. 3. Install the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 4. Install the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 5. Route the antenna cable along the path of the old antenna wiring harness, securing where necessary. 6. Install the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Installation. 7. Install the passenger side quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 8. Install the passenger side scuff plates See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Installation. 9. Install the passenger side C-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 10. Install the antenna base to the roof of the vehicle. 11. Install the antenna bracket and mounting fastener. 12. Install the antenna cable(s). 13. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 14. Connect the battery negative cable. SATELLITE AUDIO AND VIDEO AUDIO CABLE TO MODULE NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Connect the antenna cable to the module located under the front passenger seat. 2. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. 3. Install the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Installation. 4. Install the passenger side quarter trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Install the passenger side scuff plates See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Installation. 6. Install the passenger side C-pillar See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 7. Install the antenna base to the roof of the vehicle. 8. Install the antenna bracket and mounting fastener. 9. Install the antenna cable(s). 10. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 11. Position the passenger seat to its original position. 12. Connect the battery negative cable. VIDEO CABLE TO MODULE NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Connect the antenna cable to the module located under the passenger seat. 2. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. 3. Install the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Installation. 4. Install the front passenger side scuff plate See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Installation. 5. Install the antenna base to the roof of the vehicle. 6. Install the antenna bracket and mounting fastener. 7. Install the antenna cable(s). 8. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 9. Position the passenger seat to its original position. 10. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 7842 SIGNAL (RADIO FEED) ANTENNA CABLE FROM MODULE TO COWL NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Connect the antenna cable to the instrument panel antenna cable in the cowl area. 2. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. 3. Connect the antenna cable to the module. 4. Install the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Installation. 5. Install the front passenger side scuff plate See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Installation. 6. Position the passenger seat to its original position. 7. Connect the battery negative cable. SIGNAL (RADIO FEED) ANTENNA FROM COWL TO RADIO NOTE: The antenna cables are integrated into the body wiring harnesses. New antenna cables is overlaid on the body wiring harness. 1. Connect the antenna to the radio. 2. Route the antenna cable along the path of the old audio antenna wiring harness, securing where necessary. 3. Install the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 4. Install the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 5. Install the passenger side cowl panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Cowl Trim Panel Installation. 6. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Transponder Key - Description Alarm System Transponder: Description and Operation Transponder Key - Description DESCRIPTION The Sentry Key Immobilizer System (SKIS) has a transponder chip included on the circuit board beneath the cover of each FOB with Integrated Key (FOBIK) (1) included with the vehicle. The FOBIK includes an integral mechanical valet key which is stored within the bottom of the FOBIK housing until it is released using the latch button (2). The valet key is cut to match the mechanical coding of the door and glove box lock cylinders. Each new replacement FOBIK must be programmed for operation of the Remote Keyless Entry (RKE) system and has a unique transponder identification code that is permanently programmed into it by the manufacturer. This identification code must be programmed into the Wireless Ignition Node (WIN) to be recognized by the SKIS as a valid key. The FOBIK transponder cannot be adjusted or repaired. If ineffective or damaged, the entire FOBIK and RKE transmitter unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Transponder Key - Description > Page 7848 Alarm System Transponder: Description and Operation Transponder Key - Operation OPERATION When the ignition switch is turned to the ON position, the Wireless Ignition Node (WIN) communicates through its antenna with the Sentry Key transponder within the FOB with Integrated Key (FOBIK) using a Low Frequency (LF) signal. The Sentry Key transponder chip is within the range of the WIN transceiver antenna ring when it is inserted into the ignition switch. The WIN determines whether a valid FOBIK is present in the ignition switch based upon the signal from the transponder. If a valid FOBIK is detected, that fact is communicated by the WIN to the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus, and the PCM allows the engine to start. If the PCM receives an invalid key message, or receives no message from the WIN over the CAN data bus, the engine will be disabled. The Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) will also respond to the invalid key message on the CAN data bus by flashing the security indicator ON and OFF. Each Sentry Key FOBIK has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the WIN has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key FOBIK is programmed into the memory of the WIN, the WIN stores the transponder identification code from the Sentry Key FOBIK and the Sentry Key FOBIK learns the Secret Key code from the WIN. Once the Sentry Key FOBIK learns the Secret Key code of the WIN, it is permanently stored in the memory of the transponder. Therefore, once a FOBIK has been programmed to a particular vehicle, it cannot be used on any other vehicle. The Sentry Key Immobilizer System (SKIS) performs a self-test each time the ignition switch is turned to the ON position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in WIN memory if a Sentry Key FOBIK transponder problem is detected. The Sentry Key FOBIK transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7852 Hood Sensor/Switch (For Alarm): Diagrams Connector - (FRONT END MODULE) 2 WAY SWITCH-HOOD AJAR - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 7855 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (3) from the switch connector receptacle. 4. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 7858 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation SWITCH NOTE: Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit. 1. Position the hood ajar switch (1) above the hole in the mounting bracket (2). 2. Press the switch into the mounting hole until the integral switch latch tabs lock it into place. 3. Connect the harness connector (3) to the switch connector receptacle. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7863 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7864 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description Keyless Start Antenna: Description and Operation Remote Start Antenna - Description DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the Wireless Ignition Node (WIN) (1), a length of coaxial cable (2), two mounting clips (3 and 4) and a control module/antenna (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description > Page 7870 Keyless Start Antenna: Description and Operation Remote Start Antenna - Operation OPERATION The remote start antenna is an external hidden antenna located at the driver's side front of dash. The antenna interfaces with the Wireless Integration Node (WIN) through a coaxial electrical cable and electrical connector. The antenna helps to amplify the signal for the Remote Keyless Entry (RKE) key fob. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. Failure to do this may result in serious or fatal injury. The remote start antenna is located driver's side front of dash. 1. Disconnect and isolate the battery negative cable. 2. Remove radio. Refer to See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 3. Remove instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 4. Remove the instrument panel top pad. Refer to See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. NOTE: During removal of the remote start antenna note the routing location of the coaxial cable. 5. Disconnect remote start antenna coaxial cable connector (1) from skreem module (3). 6. Remove the mounting clip (2). 7. Remove the mounting clip at the steering column reinforcement bracket. 8. Remove screws (1) and remove remote start antenna (2) from instrument panel assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal > Page 7873 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION NOTE: Make sure the remote start antenna is positioned the same way noted during the removal procedure. 1. Install the remote start antenna (2) and screws (1) to instrument panel assembly. Tighten to 2.5 Nm (22 in. lbs.). 2. Route the remote start coaxial cable in the position noted during the removal procedure. 3. Install the coaxial cable mounting clip at the steering column reinforcement bracket. 4. Install the mounting clip (2). 5. Connect remote start antenna coaxial cable connector (1) to skreem module (3). 6. Install instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install radio. Refer to See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 8. Install the instrument panel top pad. Refer to See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. 9. Connect negative battery cable. Tighten to 5 Nm (45 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair FOBIK TRANSMITTER BATTERY REPLACEMENT FOBIK WITH BATTERY COVER NOTE: Do not disturb the metal terminal near the battery. Avoid touching the new battery. Skin oils may cause battery deterioration. If battery are touched, clean with rubbing alcohol. To replace the FOBIK transmitter battery: 1. Using a small flat bladed tool, carefully remove the battery cover on the back of the FOBIK. 2. Remove the battery one at a time by slightly lifting up and sliding out from the FOBIK. 3. Replace the battery with the same type of battery cell. 4. Install the battery with the positive terminal up. 5. Install battery cover and snap into place. 6. Test FOBIK operation. FOBIK WITHOUT BATTERY COVER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 7878 NOTE: Do not disturb the metal terminal near the battery. Avoid touching the new battery. Skin oils may cause battery deterioration. If battery are touched, clean with rubbing alcohol. This design is a clam shell design whereby both halves are split apart. 1. Remove the valet/spare key from the FOBIK if present. 2. Using a trim stick C-4755 or equivalent, carefully separate the top half from the bottom half. 3. Lift up on the battery to remove. 4. Replace battery with the same type of cell. 5. Install new battery negative side up. 6. Snap the top and bottom halves together. 7. Test FOBIK operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Navigation/Telecommunication - Description Cellular Phone: Description and Operation Navigation/Telecommunication - Description DESCRIPTION TELECOMMUNICATIONS The hands-free cellular system on this vehicle uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the call will be transferred to the hand-held telephone. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. The hands free module is contained within the radio for premium systems. With the low line radio, the hands free module is located on the left side of the instrument panel to the left of the steering column. NAVIGATION The navigation system offers several new customer features for expanded usability and convenience with hands-free voice-activated operation in addition to the touch screen buttons. The navigation system uses the Bluetooth microphone in the rear view mirror. Navigation routes can be based on a variety of formats including some of the following: - Destination entry by street intersection, city, zip code, street name, street address and number, state/province/country and phone number - Stop/change route - Save current position - Personal menu, including Guide Me Home (Go Home), Trip Itinerary, List of Saved Locations, Favorite Points of Interest (from a data base), Manage Personal User and Choose User - Personal Interests including recent routes, address book, Where Am I Now, Emergency (police stations, Dodge dealerships, fire stations, hospitals and emergency care centers), Trail and geocoordinates - Route options include shortest, quickest, maximize freeways, minimize freeways, avoid toll roads and avoid ferries - Navigation can be put into DEMO mode to enhance trip planning This navigation system will support Traffic Messaging. Traffic Messaging displays voice and pop up warning messages for medium and high priority situations on the route such as road closures due to accidents/hazardous situations and it can even generate a traffic detour for a traffic event located on the route. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Navigation/Telecommunication - Description > Page 7883 Cellular Phone: Description and Operation Navigation/Telecommunication - Operation OPERATION TELECOMMUNICATION Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Mobile, and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. Pressing the U Connect button accepts or rejects the call. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. NAVIGATION The navigation system collects data from GPS satellites in orbit around the Earth. This information is sent to the radio to be processed and provides the user with present location and is used to provide the route planing and guidance as the vehicle is driven. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Hands Free Module (HFM) - Removal Cellular Phone: Service and Repair Hands Free Module (HFM) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the knee bolster. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Removal. 3. Remove the hands free module mounting fasteners. 4. Disconnect the electrical connectors and remove the module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Hands Free Module (HFM) - Removal > Page 7886 Cellular Phone: Service and Repair Hands Free Module (HFM) - Installation INSTALLATION 1. Connect the electrical connectors and install the hands free module. 2. Install the hands free module mounting fasteners. 3. Install the knee bolster. See: Restraint Systems/Knee Diverter/Service and Repair/Kneeblocker - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Locations > Rear Video Camera Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Locations > Rear Video Camera > Page 7892 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Locations > Page 7893 Rear Vision Camera: Diagrams Connector (PARKVIEW) - (LIFTGATE) 6 WAY CAMERA-REAR VIDEO (PARKVIEW) - (LIFTGATE) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Description and Operation > Rear Camera - Description Rear Vision Camera: Description and Operation Rear Camera - Description DESCRIPTION The Rear View Camera (RVC) (4) (also known as Park View(TM)), is a camera on chip device utilizing Complementary Metal Oxide Semiconductor (CMOS) technology. CMOS technology is used for a wide variety of digital or analog circuits. In this application, it supports the analog image sensor of the RVC. The RVC function is to provide a wide angle video image of the area behind the vehicle, including areas that might not be normally visible from the seated position of the vehicle operator, only while the transaxle gear selector is in the Reverse position. This video image then displays to the vehicle operator within the display screen of the audio system receiver unit near the center of the instrument panel. The RVC is intended to be an auxiliary viewing aid and is not promoted as an obstacle detection or safety device. It does not remove vehicle operator responsibility to recognize and obey official traffic laws or regulations or to take sensible precautions and care to avoid pedestrians, other vehicle traffic or both fixed and moving obstacles through the habitual use of safe and defensive driving techniques. The RVC is located on the underside of the light bar (1) mounted above the license plate tub on the vehicle liftgate. The camera lens is visible just to the left of the vehicle center line, while the body of the camera and the camera connections are concealed within the light bar above a camera mounting bracket (3), to which the camera is secured with three screws. The camera mounting bracket secures to the light bar assembly to the left of the left license plate lamp (2) with two additional screws. A light bar wire harness routes through a rubber grommet into the interior of the liftgate where it connects the RVC and both license plate lamps to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Description and Operation > Rear Camera - Description > Page 7896 The camera image sensor and electronics are sealed and protected within a two-piece die cast zinc housing (1), held together by four screws (2). The camera lens (5) extends from the lower surface of the housing and an integral connector receptacle (3) containing five terminal pins that extends from the right side of the housing. Additionally, there are three mounting bosses (4) integral to the camera housing, two on the left side and one on the right. The mounting bosses receive the three self-tapping screws securing the unit to the camera bracket. Hardwired circuitry connects the RVC to the electrical system of the vehicle. These hardwired circuits are integral to several wire harnesses, which routes throughout the vehicle and retained by many different methods. These circuits may be connected to each other and to the vehicle electrical system through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The RVC cannot be adjusted or repaired. If the RVC is damaged or ineffective, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Description and Operation > Rear Camera - Description > Page 7897 Rear Vision Camera: Description and Operation Rear Camera - Operation OPERATION The Rear View Camera (RVC) is powered by a battery feed received through the backup lamp switch output circuit from the Totally Integrated Power Module (TIPM) so that is only active when the transaxle is shifted into the REVERSE position. In addition, the radio receiver monitors messages on the Controller Area Network (CAN) data bus to determine the selected transaxle gear and overrides any other display to show the RVC video output, whenever it detects that the transaxle is in REVERSE. A momentary blank video display screen immediately following the gearshift transition into the REVERSE position is considered normal operation. The camera electronics receive a path to ground at all times through a takeout and eyelet terminal of the liftgate wire harness that is secured by a ground screw to the right side of the liftgate inner panel. The output of the camera is a video signal compatible to the National Television System Committee (NTSC) standard composite video M format, or NTSC-M. The video signal is delivered to the radio video display unit through the entire length of the vehicle by camera signal and the camera return circuits that are arranged as a twisted pair, with an additional grounded foil jacket to protect the video signal from corruption due to stray radiated signals within the vehicle environment. The ground shield is terminated only at the video display (radio) end, not at the camera. Portions of these video signal wires are contained within the liftgate lightbar wire harness, the liftgate wire harness, the body wire harness and a jumper harness located between the radio and the body harness connector below the instrument panel at the right cowl side inner panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Rear Vision Camera: Symptom Related Diagnostic Procedures REAR CAMERA INOPERATIVE For a complete wiring diagram, Refer to the Wiring Information See: Diagrams/Electrical Diagrams. - When Monitored: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 7900 Ignition on, vehicle in reverse. - Set Condition: No rear picture is displayed on radio with the vehicle in reverse. 1. VERIFY OPERATION OF THE RADIO AND BACKUP LAMPS 1. Verify the operation of the Radio and Backup Lamps. Do the Radio and Backup Lamps operate correctly? Yes - Go To 2 No - Diagnose any problems with the Radio and Backup Lamps. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 2. (L1) BACKUP LAMP FEED CIRCUIT 1. Turn the ignition off. 2. Apply the parking brake. 3. Disconnect the Rear Video Camera harness connector. 4. Turn the ignition on. 5. Shift the vehicle into reverse. 6. Measure the voltage of the (L1) Backup Lamp Feed circuit. Is battery voltage present? Yes - Go To 3 No Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 7901 - Using the wiring diagrams as a guide, repair the (L1) Backup Lamp Feed circuit for an open. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 3. (Z913) GROUND CIRCUIT 1. Turn the ignition off. 2. Measure the resistance between ground and the (Z913) Ground Circuit. Is the resistance below 10.0 Ohms? Yes - Go To 4 No - Using the wiring diagrams as a guide, repair the (Z913) Ground circuit for an open. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 4. CAMERA SIGNAL, RETURN, AND SHIELD CIRCUITS OPEN 1. Disconnect the Radio C3 harness connector. 2. Measure the resistance of the (X970) (X971) and (X972) circuits. Is the resistance below 10.0 Ohms on the (X970) (X971) or (X972) circuits? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 7902 Yes - Go To 5 No - Using the wiring diagrams as a guide, repair the appropriate circuit for an open. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 5. CAMERA SIGNAL, RETURN, AND SHIELD CIRCUITS SHORTED TO GROUND 1. Measure the resistance between ground and the (X970) (X971) and (X972) circuits. Is the resistance below 10.0 Ohms on the (X970) (X971) or (X972) circuits? Yes - Using the wiring diagrams as a guide, repair the appropriate circuit for a short to ground. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. No - Replace the Rear Video Camera. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 7903 Rear Vision Camera: Component Tests and General Diagnostics Rear Camera The hardwired circuits of the Rear View Camera (RVC) and those between the RVC and the radio receiver may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RVC or the radio receiver. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to radio receiver operation, as well as the retrieval or erasure of a DTC requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: Be certain to confirm both of the following prior to attempting any further diagnosis or testing of the RVC. Use a diagnostic scan tool to confirm the rear view camera is setup in the vehicle configuration. From the initial start up screen of the diagnostic scan tool, navigate to ECU VIEW, select TIPMCGW CENTRAL GATEWAY, MORE OPTIONS, ECU DETAILS and then CONFIG INFO. Verify that REAR CAMERA PRESET - - - SET is present. If not, the Sales Code XAC (Park View Rear Back-Up Camera) will have to be added to the vehicle configuration to enable the RVC, in vehicles equipped with a MyGIG multimedia entertainment system (Sales Codes RE1, REN, REP, RER, REU, REW, REX or REZ), be certain that the RVC is set to ENABLED using the CAMERA SETUP option in the MyGIG system settings. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 7904 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Service and Repair > Rear Camera - Removal Rear Vision Camera: Service and Repair Rear Camera - Removal REMOVAL 1. Disconnect the negative battery cable. 2. Remove the four retainers (1) holding the lightbar (5) to the liftgate (6). 3. Using a trim stick or equivalent, release the lightbar (5) from the clips. 4. Disconnect the electrical connectors from the backup camera (2) and the lights (3). 5. Disconnect the liftgate release cable (4) from the lightbar (5). 6. Remove the retainer from the back of the camera. 7. Unclip the camera cover from the lightbar. 8. Remove the camera mounting retainers. 9. Remove the camera from the lightbar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Service and Repair > Rear Camera - Removal > Page 7907 Rear Vision Camera: Service and Repair Rear Camera - Installation INSTALLATION 1. Install the camera to the lightbar. 2. Install the camera mounting retainers. 3. Clip the camera cover to the lightbar. 4. Install the retainer to the back of the camera. 5. Connect the liftgate release cable (4) to the lightbar (5). 6. Connect the electrical connectors to the backup camera (2) and the lights (3). 7. Install the lightbar to the tailgate. 8. Install the four retainers (1) holding the lightbar (5) to the liftgate (6). 9. Connect the negative battery cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Driver/Vehicle Information Display: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 7912 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 Driver/Vehicle Information Display: Electrical Diagrams OVERHEAD CONSOLE - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 Overhead Console 8W-49-01 (Except Navigation) Overhead Console 8W-49-02 (Navigation) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 Overhead Console 8W-49-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Description DESCRIPTION The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel (2) and engine temperature (1) gauges. The display in the lower right part of the instrument cluster (15) below the tachometer (13) shows the vehicle odometer related functions. These functions include Trip Odometer (ODO), Trip A and Trip B readouts. The instrument cluster pushbutton (21) can be used to scroll through the different odometer functions. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Description and Operation/Instrument Cluster - Description for additional information on the instrument cluster and related functions. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display. It is located in the instrument cluster below the fuel and temperature gauges. Vehicles equipped with steering wheel-mounted buttons (described) are also equipped with the EVIC. The EVIC consists of the following: - System Status - Vehicle information warning message displays - Tire Pressure Monitor System (TPM) - If Equipped - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions The EVIC system is comprised of several different components. Those components are: - Instrument Cluster (sometimes referred to as Cab Compartment Node [CCN]) - ASBM EVIC Function Buttons - Ambient Temperature Sensor - Remote Compass Module (RCM) - Controller Area Network (CAN) Data Bus - Local Interface Network (LIN) Data Bus The EVIC display is part of the Instrument Cluster assembly and is not serviced as a separate component. If the display is inoperative the complete Instrument Cluster assembly must be replaced, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 7934 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the "ON" position. When the ignition switch is turned to the "ON" position, the EVIC display will return to the last function being displayed before the ignition was turned to the "OFF" position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC function buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button allows the driver to select the Compass/Temperature, Trip Computer, Personal Settings or System Status functions. The STEP button is used to toggle through options or features of the Trip Computer, Personal Settings or System Status functions. Pressing and releasing the RESET button allows the selection of setting or resetting of the function currently displayed at that time. Pressing and releasing the C/T (compass/temperature) button will cause the EVIC to return to the compass/temperature display mode from any other mode. EVIC DISPLAY MODES SYSTEM STATUS MODE System display mode displays warnings and user interaction messages on the EVIC display. The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - Turn Signal On (with a continuous warning chime if the vehicle is driven more than 1 mile [1.6 km] with either turn signal on) - Left Front Turn Signal Lamp Out (with a single chime) - Left Rear Turn Signal Lamp Out (with a single chime) - Right Front Turn Signal Lamp Out (with a single chime) - Right Rear Turn Signal Lamp Out (with a single chime) - RKE (Remote Keyless Entry ) Battery Low (with a single chime) - Channel # Transmit. - Channel # Training. - Channel # Trained. - Clearing Channels. - Channels Cleared. - Did Not Train. - Left Front Low Pressure (with a single chime). - Left Rear Low Pressure (with a single chime). - Right Front Low Pressure (with a single chime). - Right Rear Low Pressure (with a single chime). - Check TPM System (with a single chime). - Low Fuel - Cal - Oil Change Required (with a single chime) - Low Washer Fluid - Coolant Low - Key in Ignition - Lights On PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. Pressing and releasing the STEP button will scroll through the following personal settings choices: - Language When in this display you may select one of three languages for all display nomenclature, including the trip functions and the navigation system (if equipped). Press the RESET button while in this display to select English, Espanol, or Francais. Then, as you continue, the information will display in the selected language. NOTE: The EVIC will not change the UConnect(TM) language selection. - Unlock Doors Automatically on Exit When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Remote Key Unlock When DRIVER DOOR 1ST PRESS is selected, only the driver's door will unlock on the first press of the remote keyless Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 7935 entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. When ALL DOORS 1ST PRESS is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "Driver Door 1st Press" or "All Doors 1st Press" appears. - Sound Horn with Remote Key Lock When ON is selected, a short horn sound will occur when the remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Flash Lights with Remote Key Lock When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Delay Turning Headlights Off When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears. - Headlights On with Wipers (Available with Auto Headlights Only) When this feature is selected and the headlight switch is in the AUTO position, the headlights will activate approximately 10 seconds after the wipers are turned on. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Delay Power Off to Accessories Until Exit When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped), power sunroof (if equipped), and power outlets will remain active for up to 10 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," or "10 min." appears. Confirmation of Voice Commands - If Equipped When ON is selected, all voice commands from the UConnect(TM) system are confirmed. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Display Units of Measure in The EVIC, odometer, and navigation system (if equipped) can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears. COMPASS/TEMPERATURE Compass heading and outside temperature are displayed on the EVIC display screen. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and one of 15 compass variance settings can be programmed. Outside temperature is displayed in °C (degrees Celsius) or °F (degrees Fahrenheit). For additional information regarding the compass, refer to Personal Settings (Customer Programmable Features). TRIP COMPUTER Press and release the MENU button until one of the following Trip Functions displays in the EVIC: - Average Fuel Economy - Distance To Empty - Elapsed Time - Display Units of Measure in Press the STEP button to cycle through all the Trip Computer functions. The Trip Functions mode displays the following information: - Average Fuel Economy Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. - Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. DTE cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. - Elapsed Time Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. - Display Units of Measure in: To make your selection, press and release the RESET button until "US" or "METRIC" appears. To Reset The Display Reset will only occur while a resettable function is being displayed. Press and release the RESET button once to clear the resettable function being displayed. To reset all resettable functions, press and release the RESET button a second time within 3 seconds of resetting the currently displayed function (>Reset ALL will display during this 3 second window). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 7936 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not receive. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN and LIN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). Should the RCM become disconnected, the instrument cluster display will go blank. The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the Instrument Cluster, the RCM, the CAN Data Bus and the LIN Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration Driver/Vehicle Information Display: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. NOTE: Calibration is required anytime a new RCM is installed. Upon installation of the new RCM the "CAL" message will appear in the Electronic Vehicle Information Center (EVIC) display. The RCM will automatically calibrate if the vehicle is driven in two or more circles, slowly, and away from large metal objects. The RCM can also be calibrated by performing the following procedure. NOTE: Confirmation that the proper variance zone is programmed, is recommended whenever manual compass calibration is performed. See: for the appropriate procedure. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (4) several times until "Calibrate Compass (Yes)" is displayed. 4. Momentarily depress and release the RESET push button (3) to initiate the calibration procedure. The "CAL" symbol will come on solid in the EVIC display. 5. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" symbol will disappear from the display to indicate successful compass calibration. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 7939 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance will need to be updated to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 7940 2. Turn the ignition switch to the ON/RUN position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (4) until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. 4. Press and release the RESET push button (3) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. NOTE: The default for the compass variance from the factory is 8. During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. Press and release the Compass Temperature (C/T) push button (2) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING DEGAUSSING TOOL #6029 A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel of the vehicle. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the vehicle. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass, See: Adjustments and adjust the compass variance, See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7943 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry the switch and bezel assembly (3) away from the steering wheel at the inner retaining tab (1) and the outer bezel edge (2). 4. With the switch and bezel assembly free from the steering wheel, lift the assembly up and disconnect the switch electrical connector. 5. Using trim stick (special tool # C-4755) or equivalent, gently pry the switch bezel retainers (2) away from the switch tabs (1), while applying pressure to the back side of the switch. Remove the switch from the bezel. Electronic Vehicle Information Center Switch - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7944 1. Position the steering wheel switch onto the switch bezel aligning the switch tabs (1) with the bezel retainers (2). 2. Press the switch into the bezel, until the switch is held in place by all four retainers. 3. Position the switch and bezel assembly (3) over the steering wheel and connect the switch electrical connector. 4. Align the switch bezel tab (1) with the slot in the steering wheel and press the switch and bezel assembly (3) into the steering wheel until it is secured in place. 5. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Restraints System Verification Test. 7. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 7945 Driver/Vehicle Information Display: Tools and Equipment SPECIAL TOOLS DE GAUSER - 6029 RF Detector - 9001 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Diagrams > Satellite Video Antenna 1 (Body) 2 Way Antenna, TV: Diagrams Satellite Video Antenna 1 (Body) 2 Way Connector - (BODY) 2 WAY ANTENNA-SATELLITE VIDEO 1 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Diagrams > Satellite Video Antenna 1 (Body) 2 Way > Page 7952 Antenna, TV: Diagrams Satellite Video Antenna 2 (Body) 2 Way Connector - (BODY) 2 WAY ANTENNA-SATELLITE VIDEO 2 - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Description and Operation > Satellite Video Antenna - Description Antenna, TV: Description and Operation Satellite Video Antenna - Description DESCRIPTION The satellite video antenna cable connects the roof mounted antenna to the satellite receiver. It has two connectors at each end and is routed above the headliner, then down the right side A-pillar to the cowl area. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Description and Operation > Satellite Video Antenna - Description > Page 7955 Antenna, TV: Description and Operation Satellite Video Antenna - Operation OPERATION The satellite video antenna receives signals from orbiting satellites and sends these signals to the satellite receiver module. The satellite video antenna must have open space in which to operate. Items carried on the roof, parking inside etc. can have an effect on the antenna's ability to receive signals. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna - Removal Antenna, TV: Service and Repair Satellite Video Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the appropriate portion of the headliner as necessary, to access the underside of the antenna. 3. Disconnect the electrical connectors from the antenna. 4. Remove the fastener and retainer. 5. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna - Removal > Page 7958 Antenna, TV: Service and Repair Satellite Video Antenna - Installation INSTALLATION 1. From inside the vehicle, using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. 2. Connect the electrical connector to the antenna. 3. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 4. Connect battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Locations > Auxiliary Audio/Video Port Auxiliary Input / Output Jack: Locations Auxiliary Audio/Video Port Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Locations > Auxiliary Audio/Video Port > Page 7963 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Locations > Auxiliary Audio/Video Port > Page 7964 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Auxiliary Audio/Video Port (Rear Console) 8 Way Auxiliary Input / Output Jack: Diagrams Auxiliary Audio/Video Port (Rear Console) 8 Way Connector - (REAR CONSOLE) 8 WAY PORT-AUXILIARY AUDIO VIDEO - (REAR CONSOLE) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Auxiliary Audio/Video Port (Rear Console) 8 Way > Page 7967 Auxiliary Input / Output Jack: Diagrams Media Port (UCI) (Instrument Panel) 16 Way Connector (UCI) - (INSTRUMENT PANEL) 16 WAY PORT-MEDIA (UCI) - (INSTRUMENT PANEL) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations > Video Screen Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations > Video Screen Module > Page 7972 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Video Screen Module C1 (DVD) (Headliner) 22 Way Television / Monitor: Diagrams Video Screen Module C1 (DVD) (Headliner) 22 Way Connector C1 (DVD) - (HEADLINER) 22 WAY MODULE-VIDEO SCREEN (DVD) - (HEADLINER) 22 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Video Screen Module C1 (DVD) (Headliner) 22 Way > Page 7975 Television / Monitor: Diagrams Video Screen Module C3 (Satellite Video) (Headliner) 22 Way Connector C3 (SATELLITE VIDEO) - (HEADLINER) 22 WAY MODULE-VIDEO SCREEN (SATELLITE VIDEO) - (HEADLINER) 22 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Video Screen Module C1 (DVD) (Headliner) 22 Way > Page 7976 Television / Monitor: Diagrams Video Screen Module C4 (DVD) (Headliner) 10 Way Connector C4 (DVD) - (HEADLINER) 10 WAY MODULE-VIDEO SCREEN (DVD) - (HEADLINER) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Service and Repair > Media System Monitor - Removal Television / Monitor: Service and Repair Media System Monitor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the video screen to access the mounting fasteners. 3. Remove the mounting fasteners. 4. If equipped, disconnect the rear heat control connector (1). 5. Disconnect the video monitor connectors (2) and remove the assembly from the vehicle. 6. Remove the fasteners (1) and remove the rear A/C and heater control. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Service and Repair > Media System Monitor - Removal > Page 7979 Television / Monitor: Service and Repair Media System Monitor - Installation INSTALLATION 1. Install the rear A/C and heater control and the fasteners (1). 2. If equipped, connect the rear A/C and heater control connector (1). 3. Connect the video monitor connectors (2). 4. Install the mounting fasteners. 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Entertainment System - Disabling Front Seat Video Source DVD Player: Technical Service Bulletins Entertainment System - Disabling Front Seat Video Source NUMBER: 08-004-10 GROUP: Electrical DATE: March 2, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-002-2007 DATED FEBRUARY 6, 2007. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Radio Video Disable Update MODELS: 2010 (D1) Ram Truck (3500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2008 - 2009 (HB) Durango 2008-2009 (HG) Aspen 2008-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2007 - 2010 (JS) Sebring/Avenger/Sebring Convertible 2007-2010 (KA) Nitro 2008-2010 (KK) Liberty 2008 - 2010 (LC) Challenger 2008 - 2010 (LX) 300/ 300C, Charger 2009-2010 (MK) Patriot 2008-2010 (ND) Dakota 2008-2010 (PM) Caliber 2008 - 2010 (RT) Town & Country/Grand Caravan 2008 - 2010 (WK) Grand Cherokee 2008 - 2010 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a Hard Drive Radio (sales code REN, RER, REU, RBZ, RHR). NOTE: Refer to Warranty Bulletin D-07-04 for additional information and a listing of affected states. DISCUSSION: Due to certain state regulations, a function for disabling the front seat video option has been incorporated into the vehicle. This function will enable or disable the radio's ability to play video in the front seat. If enabled, the radio will play video when the vehicle is in Park (Automatic Transmission) or when the parking brake is set and vehicle speed is zero (Manual Transmission). If disabled the radio will NOT play video in the front seat in any operating mode. If it becomes necessary to disable the front seat video option, use the following procedure. NOTE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Entertainment System - Disabling Front Seat Video Source > Page 7984 Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. 1. Connect the wiTech 2. From the Home Screen select Radio 3. Select "Misc. Functions" 4. Select "Enable/Disable Front Seat Video" 5. Select "Enable" or "Disable" as required by your state laws. 6. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way Entertainment System Control Module: Diagrams Satellite Video Module C2 (Body) 2 Way Connector C2 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 7990 Entertainment System Control Module: Diagrams Satellite Video Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 7991 Entertainment System Control Module: Diagrams Satellite Video Module C1 (Body) 16 Way Connector C1 - (BODY) 16 WAY MODULE-SATELLITE VIDEO - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 7992 Entertainment System Control Module: Diagrams Satellite Video Module C4 (Body) 2 Way Connector C4 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal Entertainment System Control Module: Service and Repair Satellite Video Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Move the front passenger seat to the most forward position. 3. Disconnect the three antenna connectors (1) and the electrical connector (2). 4. Remove the three retainers (1) securing the video module housing (2) to the floor, remove video housing and module from vehicle. 5. Remove the video module retainers (1) to the video module housing (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal > Page 7995 Entertainment System Control Module: Service and Repair Satellite Video Module - Installation INSTALLATION 1. Install the video module to the housing. 2. Install the video module into the vehicle and Install the three retainers (1) securing the video module housing (2) to the floor.Tighten to 6 Nm (53 in. lbs.). 3. Connect the three antenna connectors (1) and the electrical connector (2). 4. Move the front passenger seat back to the original position. 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Universal Transmitter - Description Garage Door Opener Transmitter: Description and Operation Universal Transmitter - Description DESCRIPTION Some vehicles are equipped with the HomeLink(R) transceiver (1). The transceiver is located in the driver side sun visor assembly (2). The only visible component of the HomeLink(R) transceiver are the three push buttons. The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three HomeLink(R) transceiver push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 280 to 418 MegaHertz (MHz) frequency range for remote operation. The transceiver is capable of operating systems using either rolling code or non-rolling code technology. The system will not transmit operating signals if the Vehicle Theft Security System is armed. The HomeLink(R) transceiver cannot be repaired, and is available for service only with the visor assembly. If any part of the component is inoperative or damaged, the complete visor assembly must be replaced, See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair/Visor - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Universal Transmitter - Description > Page 8000 Garage Door Opener Transmitter: Description and Operation Universal Transmitter - Operation OPERATION The HomeLink(R) transceiver operates on a direct battery feed so the unit will remain functional, regardless of the ignition switch position. The transceiver has a security ground and will become disabled any time the vehicle security alarm is armed. For more information on the features, programming procedures and operation of the HomeLink(R) transceiver, see the owner's manual in the vehicle glove box. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Garage Door Opener Transmitter: Component Tests and General Diagnostics HOMELINK TRANSCEIVER RADIO FREQUENCY DETECTOR If the HomeLink(R) transceiver is inoperative, retrain the transceiver with a known good transmitter, insuring the transmitter battery is OK, See: Programming and Relearning. Test the universal transmitter operation again. If the unit is still inoperative, test the universal transmitter with Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON (3). A "chirp" will sound and the green power Light Emitting Diode (LED) will light (2). If the green LED does not light, replace the battery (4). 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs (1) will light and the tool will beep if a radio signal is detected. Repeat this test for all three transmitter buttons. If the tool does not detect a radio signal for any of the three buttons, replace the inoperative HomeLink(R) transceiver assembly, See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair/Visor - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8003 Garage Door Opener Transmitter: Programming and Relearning Programming Homelink(R) Transceiver Codes PROGRAMMING HOMELINK(R) TRANSCEIVER CODES WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. NOTE: When programming a garage door opener, it is advised to park outside the garage. It is also recommended that a new battery be placed in the hand-held transmitter of the device being programmed to the HomeLink(R) transceiver for quicker training and accurate transmission of the radio-frequency signal. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, refer to the Owner's Manual for the current customer assistance phone number. - Press and hold the two outer HomeLink(R) transceiver buttons, and release only when the indicator light begins to flash (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink(R) transceiver buttons. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver buttons while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter button. Do not release the buttons until step 4 has been completed.NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - The HomeLink(R) transceiver indicator light will flash slowly and then rapidly after HomeLink(R) successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to rapid flash. - Press and hold the just trained HomeLink(R) transceiver button and observe the indicator light. If the indicator light stays on constantly, programming is complete and your device should activate when the button is pressed and released. NOTE: To program the remaining two buttons, begin with "Programming" step 2. Do not repeat step 1. If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Programming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.)NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. The HomeLink(R) transceiver should now activate your rolling code equipped device. NOTE: To program the remaining two HomeLink(R) transceiver buttons, begin with "Programming" step 2. Do not repeat step 1. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for the HomeLink(R) transceiver to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming HomeLink(R) Transceiver Codes" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) transceiver button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted. The indicator light will flash slowly and then rapidly. Proceed with "Programming" step 4 to complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8004 Erasing Homelink(R) Transceiver Codes ERASING HOMELINK(R) TRANSCEIVER CODES NOTE: Individual channels cannot be erased. Erasing the HomeLink(R) transceiver codes will erase ALL programmed codes. To erase programming from all three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(R) transceiver buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming" See: . Reprogramming Homelink(R) Transmitter Codes REPROGRAMMING HOMELINK(R) TRANSCEIVER CODES WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the HomeLink(R) transceiver. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, refer to the Owner's Manual for the current customer assistance phone number. To program a device to the HomeLink(R) transceiver using a button previously trained, follow these steps: - Press and hold the desired HomeLink(R) transceiver button. DO NOT release the button. The indicator light will begin to flash after 20 seconds. Without releasing the HomeLink(R) transceiver button, proceed to step 2. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver button while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed.NOTE: Some gate operators and garage door openers may require you to replace this Reprogramming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - The HomeLink(R) transceiver indicator light will flash slowly and then rapidly after it successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. - Press and hold the just trained HomeLink(R) transceiver button and observe the indicator light. If the indicator light stays on constantly, reprogramming is complete and your device should activate when the button is pressed and released. NOTE: If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Reprogramming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.)NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the reprogrammed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the reprogramming. The HomeLink(R) transceiver should now activate your rolling code equipped device. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for the HomeLink(R) transceiver to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Reprogramming HomeLink(R) Transceiver Codes" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8005 - 3. Continue to press and hold the HomeLink(R) transceiver button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted. The indicator light will flash slowly and then rapidly. Proceed with "Programming" step 4 to complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 8009 Integrated Accessory Switch Assembly: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY SWITCH-BANK - (INSTRUMENT PANEL) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation > Instrument Cluster Switch Pod - Description Integrated Accessory Switch Assembly: Description and Operation Instrument Cluster Switch Pod Description DESCRIPTION The Accessory Switch Bank Module (ASBM) is located in the center stack area of the instrument panel just below the heater and air conditioner duct and above the radio. This switch is available in multiple configurations, which vary from a single momentary push button switch to as many as six momentary push button switches, depending upon the optional equipment in the vehicle. The pod may include the following switches: - Heated Seats (if equipped) (1) - Electronic Stability Program Off (2) - Hazard Warning (3) - Headlamp Leveling (export only) (4) - Electrical Inverter On/Off (domestic only) (5) The switch housing and the push buttons are constructed of molded plastic. Each push button has a smooth finish and is clearly identified with the appropriate text and International Control and Display Symbol icons. Several of the push buttons feature Light Emitting Diode (LED) units to give the vehicle operator an indication when the function of that switch is currently active. Four screws secure the switch to the back of the instrument panel center bezel through integral mounting tabs that are molded into each corner of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. Panel lamps dimmer controlled illumination lamps integral to the circuit board within the switch provide back lighting for visibility at night, but these lamps are not serviceable. The individual switches in the ASBM cannot be repaired and are not serviced individually. If any component within the switch pod is ineffective or damaged, the entire switch pod must be replaced. The Domestic version of the ASBM is as follows: - Heated Seat Switches (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - ESP Off - See: Brakes and Traction Control/Description and Operation. - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Electrical Inverter (domestic models). The Export version of the ASBM will vary from the domestic: - Heated Seat Switches (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Headlamp Leveling Switch (if equipped) - . Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. See: Service and Repair/Instrument Cluster Switch Pod - Removal. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation > Instrument Cluster Switch Pod - Description > Page 8012 Integrated Accessory Switch Assembly: Description and Operation Instrument Cluster Switch Pod Operation OPERATION For information covering details of operation for the individual switches or indicator contained within the instrument panel switch pod, refer to the specific service information covering the system to which that switch or indicator belongs. - Heated Seat Switches (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - ESP On/Off (domestic models) - See: Brakes and Traction Control/Description and Operation. - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Electrical Inverter (domestic models) - Headlamp Leveling Switch (if equipped) - . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Disconnect the electrical connector from the switch by depressing the lock tab and pulling connector from the ASBM. 4. Remove the four screws (1) to the Accessory Switch Bank Module (ASBM). 5. Remove the ASBM from the instrument panel center bezel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal > Page 8015 Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Installation INSTALLATION 1. Position the accessory switch bank module (ASBM) in the center bezel and install the four screws (1). 2. Connect the electrical connector to the ASBM. Be sure the lock tab engages securely into the ASBM. 3. Install the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Radio Amplifier C1 (Body) 22 Way Amplifier: Diagrams Radio Amplifier C1 (Body) 22 Way Connector C1 - (BODY) 22 WAY AMPLIFIER-RADIO - (BODY) 22 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Radio Amplifier C1 (Body) 22 Way > Page 8022 Amplifier: Diagrams Radio Amplifier C2 (Body) 16 Way Connector C2 - (BODY) 16 WAY AMPLIFIER-RADIO - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Amplifier - Description Amplifier: Description and Operation Amplifier - Description DESCRIPTION The optional premium speaker system includes a separate audio power amplifier. The amplifier is an eight channel unit. The amplifier is located behind the right cowl trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Amplifier - Description > Page 8025 Amplifier: Description and Operation Amplifier - Operation OPERATION The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs through eight separate channels with dedicated feed and return circuits to the individual speakers. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Amplifier - Removal Amplifier: Service and Repair Amplifier - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the glove box as necessary to gain access to the amplifier. 3. Disconnect the electrical connectors. 4. Loosen the mounting fasteners and remove the amplifier and bracket. 5. Remove the amplifier from the bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Amplifier - Removal > Page 8028 Amplifier: Service and Repair Amplifier - Installation INSTALLATION 1. Install the amplifier to the mounting bracket. 2. Install amplifier. Tighten the forward screw to 3 Nm (26.5 in. lbs.) and the rear nut to 2 Nm (18 in. lbs.). 3. Connect the electrical connectors. 4. Raise the glove box. 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8034 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8035 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8036 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8039 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8040 Remote Switch: Diagrams Left Steering Wheel Switch (EVIC) (Steering Wheel) 4 Way Connector (EVIC) - (STEERING WHEEL) 4 WAY SWITCH-STEERING WHEEL-LEFT (EVIC) - (STEERING WHEEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8041 Remote Switch: Diagrams Right Steering Wheel Switch (EVIC) (Steering Wheel) 10 Way Connector (EVIC) - (STEERING WHEEL) 10 WAY SWITCH-STEERING WHEEL-RIGHT (EVIC) - (STEERING WHEEL) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8042 Remote Switch: Description and Operation DESCRIPTION Remote radio control switches are rocker-type switch units are mounted in the upper spoke covers of the rear (instrument panel side) steering wheel trim cover. The switch unit on the left side is the seek switch and has seek up, seek down, and preset station advance switch functions. The switch unit on the right side is the volume control switch and has volume up, volume down, and mode advance switch functions. The two remote radio switch units are each retained in a mounting hole located on opposite sides of the rear steering wheel trim cover by four integral snap features. A plastic bracket on the back of each switch unit provides additional support for the unit by extending towards the center of the steering wheel where it is clamped between the steering wheel armature and the steering wheel rear trim cover mounting boss by the trim cover mounting screw. The two remote radio switch units share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8043 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test table. If the remote radio switch resistances check OK, go to 3. If not OK, replace the faulty switch. REMOTE RADIO SWITCH TEST 3. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for 5 volts at the radio control circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, refer to the proper Body Diagnostic Procedures. If not OK, repair the circuit as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Disconnect the horn connector (3). 4. Remove retainers (1) and remove the horn button assembly (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 8046 5. Remove the speed control switch (3) See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Removal. 6. Disconnect the radio switches (1). 7. From the inside of the steering wheel rear trim cover, press firmly and evenly outward on the back of the switch to disengage the four snap features that secure the switch to the inside of the mounting hole. 8. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 8047 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch snap features is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch (1). 4. Install the speed control switch (3) See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 8048 5. Install the horn button assembly (2) and install the three retainers (1). 6. Connect the horn connector (3). 7. Install the driver side airbag module to the steering wheel See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag Installation. 8. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8053 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8054 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8055 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8056 Speaker: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8057 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8058 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8059 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8060 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8061 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Instrument Panel Speaker > Page 8062 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way Speaker: Diagrams Left Instrument Panel Speaker (Instrument Panel) 2 Way Connector - (INSTRUMENT PANEL) 2 WAY SPEAKER-INSTRUMENT PANEL-LEFT - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8065 Speaker: Diagrams Right Instrument Panel Speaker (Instrument Panel) 2 Way Connector - (INSTRUMENT PANEL) 2 WAY SPEAKER-INSTRUMENT PANEL-RIGHT - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8066 Speaker: Diagrams Left Front Door Speaker (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (FRONT DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8067 Speaker: Diagrams Left Rear Door Speaker (Rear Door) 3 Way Connector - (REAR DOOR) 3 WAY SPEAKER-LEFT REAR DOOR - (REAR DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8068 Speaker: Diagrams Left Instrument Panel Speaker (Instrument Panel) 2 Way Connector - (INSTRUMENT PANEL) 2 WAY SPEAKER-INSTRUMENT PANEL-LEFT - (INSTRUMENT PANEL) 2 WAY Right Instrument Panel Speaker (Instrument Panel) 2 Way Connector - (INSTRUMENT PANEL) 2 WAY SPEAKER-INSTRUMENT PANEL-RIGHT - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8069 Left Front Door Speaker (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (FRONT DOOR) 3 WAY Left Rear Door Speaker (Rear Door) 3 Way Connector - (REAR DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8070 SPEAKER-LEFT REAR DOOR - (REAR DOOR) 3 WAY Right Front Door Speaker (Front Door) 3 Way Connector - (FRONT DOOR) 3 WAY SPEAKER-RIGHT FRONT DOOR - (FRONT DOOR) 3 WAY Right Rear Door Speaker (Rear Door) 3 Way Connector - (REAR DOOR) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Instrument Panel Speaker (Instrument Panel) 2 Way > Page 8071 SPEAKER-RIGHT REAR DOOR - (REAR DOOR) 3 WAY Subwoofer Speaker (Premium) (Body) 6 Way Connector (PREMIUM) - (BODY) 6 WAY SPEAKER-SUBWOOFER (PREMIUM) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8072 Speaker: Description and Operation OPERATION Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8073 Speaker: Testing and Inspection SPEAKER Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. If all speakers are inoperative, check the radio fuses in the Totally Integrated Power Module (TIPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the TIPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If vehicle is equipped with an amplifier. disconnect wire harness connector at output side of amplifier. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuit(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuit(s) as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal Speaker: Service and Repair Speaker - Removal REMOVAL DOOR SPEAKER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Remove the mounting fasteners. 4. Disconnect the electrical connector and remove the speaker from the vehicle. INSTRUMENT PANEL SPEAKER 1. Disconnect and isolate the battery negative cable. 2. Remove the defroster grille. See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 3. Remove the mounting fasteners. 4. Disconnect the electrical connector and remove the speaker from the vehicle. SUBWOOFER 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the subwoofer mounting fasteners. 4. Disconnect the electrical connectors and remove the subwoofer from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 8076 Speaker: Service and Repair Speaker - Installation INSTALLATION DOOR SPEAKER 1. Install the speaker and connect the electrical connector. 2. Install the mounting fasteners. 3. Install the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. INSTRUMENT PANEL SPEAKER 1. Install the speaker and connect the electrical connector. 2. Install the mounting fasteners. 3. Install the defroster grille. See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Installation. 4. Connect the battery negative cable. SUBWOOFER 1. Install the subwoofer and connect the electrical connector. 2. Install the mounting fasteners. 3. Install the left rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way Entertainment System Control Module: Diagrams Satellite Video Module C2 (Body) 2 Way Connector C2 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 8083 Entertainment System Control Module: Diagrams Satellite Video Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 8084 Entertainment System Control Module: Diagrams Satellite Video Module C1 (Body) 16 Way Connector C1 - (BODY) 16 WAY MODULE-SATELLITE VIDEO - (BODY) 16 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C2 (Body) 2 Way > Page 8085 Entertainment System Control Module: Diagrams Satellite Video Module C4 (Body) 2 Way Connector C4 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal Entertainment System Control Module: Service and Repair Satellite Video Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Move the front passenger seat to the most forward position. 3. Disconnect the three antenna connectors (1) and the electrical connector (2). 4. Remove the three retainers (1) securing the video module housing (2) to the floor, remove video housing and module from vehicle. 5. Remove the video module retainers (1) to the video module housing (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal > Page 8088 Entertainment System Control Module: Service and Repair Satellite Video Module - Installation INSTALLATION 1. Install the video module to the housing. 2. Install the video module into the vehicle and Install the three retainers (1) securing the video module housing (2) to the floor.Tighten to 6 Nm (53 in. lbs.). 3. Connect the three antenna connectors (1) and the electrical connector (2). 4. Move the front passenger seat back to the original position. 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8092 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8093 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Hands Free Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Hands Free Module > Page 8098 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams > Hands Free Module C1 (Instrument Panel) 22 Way Voice Activation Module: Diagrams Hands Free Module C1 (Instrument Panel) 22 Way Connector C1 - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams > Hands Free Module C1 (Instrument Panel) 22 Way > Page 8101 Voice Activation Module: Diagrams Hands Free Module C2 (UCI) (Instrument Panel) 10 Way Connector C2 (UCI) - (INSTRUMENT PANEL) 10 WAY MODULE-HANDS FREE (UCI) - (INSTRUMENT PANEL) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8106 Hood Sensor/Switch (For Alarm): Diagrams Connector - (FRONT END MODULE) 2 WAY SWITCH-HOOD AJAR - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 8109 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (3) from the switch connector receptacle. 4. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 8112 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation SWITCH NOTE: Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit. 1. Position the hood ajar switch (1) above the hole in the mounting bracket (2). 2. Press the switch into the mounting hole until the integral switch latch tabs lock it into place. 3. Connect the harness connector (3) to the switch connector receptacle. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 8116 Integrated Accessory Switch Assembly: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY SWITCH-BANK - (INSTRUMENT PANEL) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation > Instrument Cluster Switch Pod - Description Integrated Accessory Switch Assembly: Description and Operation Instrument Cluster Switch Pod Description DESCRIPTION The Accessory Switch Bank Module (ASBM) is located in the center stack area of the instrument panel just below the heater and air conditioner duct and above the radio. This switch is available in multiple configurations, which vary from a single momentary push button switch to as many as six momentary push button switches, depending upon the optional equipment in the vehicle. The pod may include the following switches: - Heated Seats (if equipped) (1) - Electronic Stability Program Off (2) - Hazard Warning (3) - Headlamp Leveling (export only) (4) - Electrical Inverter On/Off (domestic only) (5) The switch housing and the push buttons are constructed of molded plastic. Each push button has a smooth finish and is clearly identified with the appropriate text and International Control and Display Symbol icons. Several of the push buttons feature Light Emitting Diode (LED) units to give the vehicle operator an indication when the function of that switch is currently active. Four screws secure the switch to the back of the instrument panel center bezel through integral mounting tabs that are molded into each corner of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. Panel lamps dimmer controlled illumination lamps integral to the circuit board within the switch provide back lighting for visibility at night, but these lamps are not serviceable. The individual switches in the ASBM cannot be repaired and are not serviced individually. If any component within the switch pod is ineffective or damaged, the entire switch pod must be replaced. The Domestic version of the ASBM is as follows: - Heated Seat Switches (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - ESP Off - See: Brakes and Traction Control/Description and Operation. - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Electrical Inverter (domestic models). The Export version of the ASBM will vary from the domestic: - Heated Seat Switches (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Headlamp Leveling Switch (if equipped) - . Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced. See: Service and Repair/Instrument Cluster Switch Pod - Removal. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Description and Operation > Instrument Cluster Switch Pod - Description > Page 8119 Integrated Accessory Switch Assembly: Description and Operation Instrument Cluster Switch Pod Operation OPERATION For information covering details of operation for the individual switches or indicator contained within the instrument panel switch pod, refer to the specific service information covering the system to which that switch or indicator belongs. - Heated Seat Switches (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description. - ESP On/Off (domestic models) - See: Brakes and Traction Control/Description and Operation. - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description. - Electrical Inverter (domestic models) - Headlamp Leveling Switch (if equipped) - . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Disconnect the electrical connector from the switch by depressing the lock tab and pulling connector from the ASBM. 4. Remove the four screws (1) to the Accessory Switch Bank Module (ASBM). 5. Remove the ASBM from the instrument panel center bezel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal > Page 8122 Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Installation INSTALLATION 1. Position the accessory switch bank module (ASBM) in the center bezel and install the four screws (1). 2. Connect the electrical connector to the ASBM. Be sure the lock tab engages securely into the ASBM. 3. Install the instrument panel center bezel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8127 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8128 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8129 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8132 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8133 Remote Switch: Diagrams Left Steering Wheel Switch (EVIC) (Steering Wheel) 4 Way Connector (EVIC) - (STEERING WHEEL) 4 WAY SWITCH-STEERING WHEEL-LEFT (EVIC) - (STEERING WHEEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8134 Remote Switch: Diagrams Right Steering Wheel Switch (EVIC) (Steering Wheel) 10 Way Connector (EVIC) - (STEERING WHEEL) 10 WAY SWITCH-STEERING WHEEL-RIGHT (EVIC) - (STEERING WHEEL) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8135 Remote Switch: Description and Operation DESCRIPTION Remote radio control switches are rocker-type switch units are mounted in the upper spoke covers of the rear (instrument panel side) steering wheel trim cover. The switch unit on the left side is the seek switch and has seek up, seek down, and preset station advance switch functions. The switch unit on the right side is the volume control switch and has volume up, volume down, and mode advance switch functions. The two remote radio switch units are each retained in a mounting hole located on opposite sides of the rear steering wheel trim cover by four integral snap features. A plastic bracket on the back of each switch unit provides additional support for the unit by extending towards the center of the steering wheel where it is clamped between the steering wheel armature and the steering wheel rear trim cover mounting boss by the trim cover mounting screw. The two remote radio switch units share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8136 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of the scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test table. If the remote radio switch resistances check OK, go to 3. If not OK, replace the faulty switch. REMOTE RADIO SWITCH TEST 3. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for 5 volts at the radio control circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, refer to the proper Body Diagnostic Procedures. If not OK, repair the circuit as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Disconnect the horn connector (3). 4. Remove retainers (1) and remove the horn button assembly (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal > Page 8139 5. Remove the speed control switch (3) See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Removal. 6. Disconnect the radio switches (1). 7. From the inside of the steering wheel rear trim cover, press firmly and evenly outward on the back of the switch to disengage the four snap features that secure the switch to the inside of the mounting hole. 8. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal > Page 8140 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch snap features is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch (1). 4. Install the speed control switch (3) See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal > Page 8141 5. Install the horn button assembly (2) and install the three retainers (1). 6. Connect the horn connector (3). 7. Install the driver side airbag module to the steering wheel See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag Installation. 8. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 8145 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 8148 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C3 (Instrument Panel) 4 Way Connector C3 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 8149 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C2 (Instrument Panel) 6 Way > Page 8150 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C8 (Steering Wheel) 6 Way Connector C8 - (STEERING WHEEL) 6 WAY MODULE-STEERING CONTROL - (STEERING WHEEL) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (1), control knob and control sleeve that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions and electrical connections are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the SCM through a jumper wire harness (5) directly to the right (wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is integral to the back of the switch housing and connects the SCM to the vehicle electrical system through a dedicated takeout and connector of the instrument panel wire harness. The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function switch must be replaced. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 8153 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 8154 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM). The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch (with integral Steering Control Module) - Right Multi-Function Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 8155 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Page 8156 Steering Mounted Controls Communication Module: Testing and Inspection STEERING CONTROL MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the Steering Control Module (SCM) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or the electronic controls or communication between modules and other devices that provide some features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 4. Remove steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 5. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM)See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 6. Lock the clockspring rotor in the center position as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove the three screws (1) to the Steering Column Control Module (SCCM) (3). 8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. NOTE: If only removing the SCCM from column, there is no need to continue to next step. DISASSEMBLY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 8159 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 8160 7. Disconnect the right switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 8161 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 8162 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 8163 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection/Component Tests and General Diagnostics . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico Towing Information: Service and Repair Trailer Towing - NAFTA, Puerto Rico SPECIFICATION - TOWING, Trailer - NAFTA, Puerto Rico you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer, carefully review this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The Gross Vehicle Weight Rating (GVWR) is the total allowable weight of your vehicle. This includes driver, passengers, cargo, and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The Gross Trailer Weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables, and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The Gross Combination Weight Rating (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 150 lbs (68 kg) allowance for the presence of a driver.) Gross Axle Weight Rating (GAWR) The Gross Axle Weight Rating (GAWR) is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. You could lose control of the vehicle and have an accident. Failure to follow these instructions may result in possible serious or fatal injury. Tongue Weight (TW) Tongue weight (TW) is the downward force exerted on the hitch ball by the trailer. In most cases, it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle. Frontal Area Frontal area is the maximum height and maximum width of the front of a trailer. Trailer Sway Control - Electronic For information on this system, See: Brakes and Traction Control/Description and Operation. Trailer Sway Control - Mechanical The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the vehicle. These kinds of hitches are the most popular on the market today and they are commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8169 Weight Distributing Hitch System A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction / hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. Trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier Tongue Weights (TW) and may be required depending on vehicle and trailer configuration / loading to comply with Gross Axle Weight Rating (GAWR) requirements. Improper Adjustment of Weight Distributing System WARNING: - An improperly adjusted weight distributing hitch system may reduce handling, stability, braking performance, and could result in an accident. - Weight distributing systems may not be compatible with surge brake couplers. Consult with your hitch and trailer manufacturer or a reputable recreational vehicle dealer for additional information. Failure to follow these instructions may result in possible serious or fatal injury. Trailer Hitch Classification Your vehicle may be factory equipped for safe towing of trailers weighing over 2,000 lbs (907 kg) with the optional Trailer Tow Prep Package. See your authorized dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition. All trailer hitches should be professionally installed on your vehicle. Trailer Towing Weights (Maximum Trailer Weight Ratings) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8170 The following chart provides the maximum trailer weight ratings towable for your given drivetrain. Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of the vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on your bumper or trailer hitch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8171 Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on your vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options or authorized dealer-installed options must be considered as part of the total load on your vehicle. Refer to the "Tire and Loading Information" placard for the maximum combined weight of occupants and cargo for your vehicle. Towing Requirements To promote proper break-in of your new vehicle drivetrain components the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 mi (805 km) of vehicle operation. Doing so may damage the vehicle. - During the first 500 mi (805 km) of trailer towing, limit the speed to 50 mph (80 km/h). WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make your trailer towing as safe as possible: Make certain that the load is secured in the trailer and that it will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. You could lose control of your vehicle and have an accident. Failure to follow these instructions may result in possible serious or fatal injury. - When hauling cargo or towing a trailer, do not overload your vehicle or trailer. Overloading can cause a loss of control, poor performance, or damage to brakes, axle, engine, transaxle, steering, suspension, chassis structure, or tires. - Safety chains must always be used between your vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transaxle in PARK. Always, block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized. (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight.) Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. - Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. Refer to "Tires-General Information" for information on tire pressures and for proper tire inflation procedures. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer. Refer to "Tires-General Information" for information on tread wear indicators and for the proper inspection procedure. - When replacing tires, See: Maintenance/Wheels and Tires/Tires/Description and Operation for information on replacement tires and for the proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (454 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 1,000 lbs (454 kg) loaded, it should have its own brakes, and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances. WARNING: Do not connect trailer brakes to your vehicle's hydraulic brake lines. It can overload your brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase your stopping distance. When towing, you should allow for additional space between your vehicle and the vehicle in front of you. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8172 Towing Requirements - Trailer Lights AND Wiring 4 - Pin Connector Whenever you pull a trailer, regardless of the trailer size, stoplights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4- and 7-pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicles wiring harness. The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations. 7- Pin Connector Towing Tips Before setting out on a trip, practice turning, stopping, and backing up the trailer in an area located away from heavy traffic. Towing Tips - Automatic Transaxle The DRIVE range can be selected when towing. However, if frequent shifting occurs while in this range, select the "3" range for 4-speed automatic or the "5" range for 6-speed automatic. NOTE: Using the "3" or "5" range while operating the vehicle under heavy operating conditions will improve performance and extend transaxle life by reducing excessive shifting and heat build up. This action will also provide better engine braking. If you REGULARLY tow a trailer for more than 45 minutes of continuous operation, then change the automatic transaxle fluid and filter according to the interval specified for "police, taxi, fleet, or frequent trailer towing" in the Maintenance Schedule. NOTE: Check the 4-speed automatic transaxle fluid level before towing. The 6-speed transaxle is sealed and the fluid level cannot be checked. See your authorized dealer for assistance. Towing Tips - Electronic Speed Control (If Equipped) - Don't use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage until you can get back to cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Towing Tips - Autostick (R) (If Equipped) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8173 - By using the Autostick(R) modes and selecting a specific gear range, frequent shifting can be avoided. The highest gear range should be selected that allows for adequate performance. For example, choose "4" if the desired speed can be maintained. Choose "3" or "2" if needed to maintain the desired speed. - Extended driving at high RPM should be avoided to prevent excess heat generation. A reduction in vehicle speed may be required to avoid extended driving at high RPM. Return to a higher gear range or vehicle speed when road conditions and RPM level allows. Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8174 Towing Information: Service and Repair Vehicle Towing TOWING, Vehicle WARNINGS AND PRECAUTIONS WARNING: Do not allow towing attachment devices to contact the fuel tank or lines, fuel leakage can result. Do not lift or tow vehicle by front or rear bumper, or bumper energy absorber units. Do not venture under a lifted vehicle if not supported properly on safety stands. Do not allow passengers to ride in a towed vehicle. Use a safety chain that is independent from the towing attachment device. Failure to follow these instructions may result in personal injury or death. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not attach towing device to front or rear suspension components. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a flat bed towing device or wheel lift is recommended. When using a wheel lift towing device, be sure the unlifted end of disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees. TOWING A DISABLED VEHICLE NUMBER: Without The Ignition Key Front Wheel Drive (FWD) Special care must be taken when the vehicle is towed with the ignition in the LOCK position. Flat bed towing is the preferred towing method. However, if a flat bed towing vehicle is not available, a wheel lift towing vehicle may be used. Furthermore, rear towing is not recommended with the front wheels on the ground, as transaxle damage can result. If rear towing is the only alternative, a front end dolly must be used. Proper towing equipment is necessary to prevent damage to the vehicle. All Wheel Drive (AWD) The vehicle must be transported on a flat bed truck. Towing This Vehicle Behind Another Vehicle (Flat Towing With The Key In The Ignition And All Four Wheels On The Ground) CAUTION: - If the vehicle being towed requires steering, the ignition switch must be in the ON position, not in the LOCK or ACC position. - Do not attempt to tow this vehicle from the front with sling type towing equipment. Damage to the front fascia will result. - Do not push or tow this vehicle with another vehicle as damage to the bumper fascia and transaxle may result. If you must use the accessories (wipers, defrosters, etc.) while being towed, the key must be in the ON position, not the ACC position. Make certain the transaxle remains in NEUTRAL. Front Wheel Drive (FWD) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8175 The vehicle may be towed under the following conditions: The shift lever must be in NEUTRAL, the distance to be traveled must not exceed 15 mi (25 km), and the towing speed must not exceed 25 mph (40 km/h). Exceeding these towing limits may cause a transaxle failure. If the transaxle is not operative, or if the vehicle is to be towed more than 15 mi (25 km), the vehicle must be transported either with a flat bed truck or with the front wheels off the ground. All Wheel Drive (AWD) The vehicle may be towed under the following conditions: The shift lever must be in NEUTRAL, the distance to be traveled must not exceed 15 mi (25 km), the towing speed must not exceed 25 mph (40 km/h), and both front and rear wheels must be on the ground. Exceeding these towing limits may cause a transaxle failure. If the transaxle is not operative, or if the vehicle is to be towed more than 15 mi (25 km), the vehicle must be transported on a flat bed truck. Towing This Vehicle Behind Another Vehicle With A Tow Dolly Front Wheel Drive (FWD) Rear towing is not recommended with the front wheels on the ground, as transaxle damage can result. If rear towing is the only alternative, a front end dolly must be used. Proper towing equipment is necessary to prevent damage to the vehicle. All Wheel Drive (AWD) CAUTION: The manufacturer does not recommend towing an All-Wheel Drive (AWD) on a tow dolly. Vehicle damage may occur. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing - NAFTA, Puerto Rico > Page 8176 Towing Information: Service and Repair Recreational Towing (Behind Motorhome, etc.) RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) Recreational Towing Chart CAUTION: ONLY vehicles equipped with a MANUAL TRANSAXLE may be recreationally towed (flat towed) at any legal highway speed, for any distance, if the MANUAL TRANSAXLE is in NEUTRAL and the ignition key is in the ACC position. CAUTION: - DO NOT FLAT TOW any vehicle equipped with an AUTOMATIC TRANSAXLE. Damage to the drivetrain will result. If these vehicles require towing, make sure all four wheels are off the ground. - Front or rear wheel lifts should not be used. Internal damage to the transaxle will occur if a front or rear wheel lift is used when recreational towing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Service and Repair Trailer Adapter Kit: Service and Repair TRAILER TOW HARNESS INSTALLATION 1. Remove the push pin fasteners (2) and separate the rear tail lamp assemblies (1). 2. Disconnect the tail lamp electrical connectors (2 and 3). 3. Connect the harness (2) to the left side tail lamp electrical connectors (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Service and Repair > Page 8180 4. Position the harness (1) through the tail lamp opening and down the side of the fender. 5. Secure the support clips (2) to the body seem. 6. Position the harness (1) over the exhaust and fasten the push pin fasteners (2) to the under side of the rear bumper in the existing holes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Service and Repair > Page 8181 7. Position the harness (1) up the right side of the vehicle to the right tail lamp opening and secure the clips (2) to the body seem. 8. Connect the harness (1) to the right side tail lamp electrical connectors (2). 9. Connect the tail lamp electrical connectors (2 and 3) to the tail lamp assemblies (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Service and Repair > Page 8182 10. Install tail lamps assemblies (1) and install the push pin fasteners (2) fully. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 Trailer Connector: Connector Views Connector - (TRAILER TOW) 4 WAY WIRING-TRAILER TOW 4-WAY - (TRAILER TOW) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 Trailer Connector: Electrical Diagrams TRAILER TOW - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 Trailer Tow 8W-54-01 Trailer Tow 8W-54-02 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description Trailer Connector: Description and Operation Trailer Tow Wiring - Description DESCRIPTION Vehicles equipped with an optional Trailer Tow Preparation package have a trailer tow wiring harness and an instruction sheet (1) that are placed in the glove box (2) of the vehicle when it is shipped from the factory. This package also includes four relays to isolate the trailer lighting from the vehicle lighting and a four-way trailer tow wiring connector that are all concealed behind the rear bumper fascia after installation is complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description > Page 8207 Trailer Connector: Description and Operation Trailer Tow Wiring - Operation OPERATION The trailer tow preparation wiring harness is connected to the body wire harness at the right and left outer rear lamp unit connections. After installation is complete, a trailer tow stop/turn relay is secured to the harness behind the rear bumper fascia just below each outer rear lamp unit, while a trailer tow stop lamp relay is located on the underside of each outboard end of the rear bumper reinforcement behind the rear fascia. The four-way trailer tow connector is located near the center of the rear fascia. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Also refer to the Instruction Sheet packaged with the harness for additional details. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8212 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8213 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8214 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Trailer Towing Relay: Diagrams Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8217 Trailer Towing Relay: Diagrams Right Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8218 Trailer Towing Relay: Diagrams Left Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8219 Trailer Towing Relay: Diagrams Right Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional trailer tow preparation package have four trailer tow relays, one each for the trailer tow stop/turn right and left and one each for the trailer stop lamp right and left. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are included with the trailer tow preparation wire harness that is shipped loose in the glove box for customer or dealer installation at the rear of the vehicle. A trailer tow stop/turn relay is located behind the rear fascia below each outer tail lamp, while a trailer stop lamp relay is located behind the rear fascia below each outboard end of the rear bumper reinforcement. Each relay and connector is wrapped within an isolator envelope for sound deadening and anti-rattle protection. Refer to the appropriate wiring information for specific relay cavity assignment information. Any of the trailer tow relays cannot be adjusted or repaired and, if ineffective or damaged, the affected unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 8222 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Totally Integrated Power Module (TIPM) to the tail lamps to control a high current output to the trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right trailer tow stop/turn signal pins of the 4-way trailer tow connector at all times. The common feed terminals of both the left and right trailer tow stop relays is connected to the normally closed (87A) terminal of their respective left or right trailer tow stop/turn relay at all times. - Coil Ground Terminal (85) - The coil ground terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. The coil ground terminals of both the left and right trailer tow stop relays are connected to the stop lamp control circuit from the TIPM at all times. - Coil Battery Terminal (86) - The coil battery terminal of both the left and right trailer tow stop/turn relays is connected to a path to ground at all times. The coil battery terminal of both the left and right trailer tow stop relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. - Normally Open Terminal (87) - The normally open terminal of both the left and right trailer tow stop/turn relays is connected to the stop lamp control circuit from the TIPM whenever that relay is energized. The normally open terminal of both the left and right trailer tow stop relays is connected to a path to ground whenever that relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal of both the left and right trailer tow stop/turn relays is connected are connected to the common supply (30) terminal of their respective left or right trailer tow stop relay whenever the relay is de-energized. The normally closed terminal of both the left and right trailer tow stop relays is not connected to any circuit in this application. The trailer tow relays and the hard wired circuits for the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that provide some features of the trailer tow turn and stop lamp lighting system. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to trailer tow turn and stop lamp lighting operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal Trailer Towing Relay: Service and Repair Trailer Tow Relay - Removal REMOVAL TRAILER TOW STOP/TURN RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal 3. Disengage the left or right trailer tow stop/turn relay and connector from the isolator envelope (3) secured to the trailer tow wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Pull the relay straight out from the wire harness connector. TRAILER TOW STOP LAMP RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal 3. Disengage the left or right trailer tow stop lamp relay and connector from the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Pull the relay straight out from the wire harness connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal > Page 8225 Trailer Towing Relay: Service and Repair Trailer Tow Relay - Installation INSTALLATION TRAILER TOW STOP/TURN RELAYS 1. Align the terminals of the left or right trailer tow stop/turn relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (3) secured to the wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Reinstall the rear fascia onto the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. TRAILER TOW STOP LAMP RELAYS 1. Align the terminals of the left or right trailer tow stop lamp relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Reinstall the rear fascia onto the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8232 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8233 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8234 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8235 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8236 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8237 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8238 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8239 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8240 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8241 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 Trailer Connector: Connector Views Connector - (TRAILER TOW) 4 WAY WIRING-TRAILER TOW 4-WAY - (TRAILER TOW) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 Trailer Connector: Electrical Diagrams TRAILER TOW - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 Trailer Tow 8W-54-01 Trailer Tow 8W-54-02 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description Trailer Connector: Description and Operation Trailer Tow Wiring - Description DESCRIPTION Vehicles equipped with an optional Trailer Tow Preparation package have a trailer tow wiring harness and an instruction sheet (1) that are placed in the glove box (2) of the vehicle when it is shipped from the factory. This package also includes four relays to isolate the trailer lighting from the vehicle lighting and a four-way trailer tow wiring connector that are all concealed behind the rear bumper fascia after installation is complete. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description > Page 8250 Trailer Connector: Description and Operation Trailer Tow Wiring - Operation OPERATION The trailer tow preparation wiring harness is connected to the body wire harness at the right and left outer rear lamp unit connections. After installation is complete, a trailer tow stop/turn relay is secured to the harness behind the rear bumper fascia just below each outer rear lamp unit, while a trailer tow stop lamp relay is located on the underside of each outboard end of the rear bumper reinforcement behind the rear fascia. The four-way trailer tow connector is located near the center of the rear fascia. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Also refer to the Instruction Sheet packaged with the harness for additional details. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Hands Free Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Hands Free Module > Page 8256 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Diagrams > Hands Free Module C1 (Instrument Panel) 22 Way Voice Activation Module: Diagrams Hands Free Module C1 (Instrument Panel) 22 Way Connector C1 - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Diagrams > Hands Free Module C1 (Instrument Panel) 22 Way > Page 8259 Voice Activation Module: Diagrams Hands Free Module C2 (UCI) (Instrument Panel) 10 Way Connector C2 (UCI) - (INSTRUMENT PANEL) 10 WAY MODULE-HANDS FREE (UCI) - (INSTRUMENT PANEL) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions Body Control Systems: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8265 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8266 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8267 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8268 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8269 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8270 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8271 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8272 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8273 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8274 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8275 Body Control Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8276 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8277 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8278 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8279 Body Control Systems: Electrical Diagrams CONVENIENCE SYSTEMS - Diagrams (PARKVIEW) PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8280 Convenience Systems 8W-56-01 (Parkview/Navigation) Convenience Systems 8W-56-02 (Parkview/Navigation) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia - Removal REMOVAL 1. Release hood latch and open hood. 2. Remove the pushpins for the fascia (2) at the radiator support. 3. Hoist and support vehicle on safety stands. See: Maintenance , for proper hoisting and jacking procedures. 4. Remove the pop rivets (2) at the wheel well opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal > Page 8287 5. Remove the torx(R) screw (3) at the wheel well housing. 6. Separate the fascia tabs (2) at the bracket (1). 7. Remove the pushpins (1) for the fascia (2) at the lower closeout panel. 8. Slide the fascia (2) out from the mounting tab (1) under the headlamp. 9. Disengage fog lamp wire connector and side marker connector from body harness, if equipped. 10. Disengage the ambient temp sensor wire connector, if equipped. 11. Remove fascia from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal > Page 8288 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia - Installation INSTALLATION 1. Install the fascia to the vehicle. 2. Reconnect the ambient temp sensor wire connector, if equipped. 3. Reconnect the fog lamp wire connector and side marker connector from body harness, if equipped. 4. Slide the fascia (2) into the mounting tab (1) under the headlamp. 5. Install the pushpins (1) for the fascia (2) at the lower closeout panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal > Page 8289 6. Insert and snap into place the fascia tabs (2) at the bracket (1). 7. Install the torx(R) screw (3) at the wheel well housing. 8. Install the pop rivets (2) at the wheel well opening. 9. Lower the vehicle. 10. Install the pushpins for the fascia (2) at the radiator support. 11. close the hood and check for proper fit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal > Page 8290 Front Bumper Cover / Fascia: Service and Repair Front Lower Fascia Closeout - Removal REMOVAL 1. Remove fasteners (5) to lower closeout. 2. Remove push pins (1) to lower closeout. 3. Remove the front lower fascia. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal > Page 8291 Front Bumper Cover / Fascia: Service and Repair Front Lower Fascia Closeout - Installation INSTALLATION 1. Install the front lower fascia. 2. Install the push pins (1) to lower closeout. 3. Install the fasteners (5) to lower closeout. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Reinforcement - Removal Front Bumper Reinforcement: Service and Repair Front Bumper Reinforcement - Removal REMOVAL 1. Remove the front fascia See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 2. Support bumper reinforcement (3) on a suitable lifting device. 3. Mark the position of the bolts (1) on frame rail to aid in installation. 4. Remove the smaller bolts (2) attaching bumper reinforcement (3) to frame rail. 5. Remove the larger bolts (1) attaching bumper reinforcement (3) to frame rail. 6. Remove bumper reinforcement (3) from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Reinforcement - Removal > Page 8296 Front Bumper Reinforcement: Service and Repair Front Bumper Reinforcement - Installation INSTALLATION 1. Position the bumper reinforcement (3) on vehicle. NOTE: Use marks made previously to properly position bumper reinforcement 2. Install the larger bolts (1) attaching bumper reinforcement (3) to frame rail. Tighten bolts (1) to 28 Nm (250 in.lbs.). 3. Install the smaller bolts (2) attaching bumper reinforcement (3) to frame rail. 4. Install front fascia See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia - Removal REMOVAL 1. Open the hatch. 2. Remove the 6 pushpins (1) securing the fascia (2). 3. Remove the rivets (2) and the torx(R) screw (3) around the wheel well for the fascia (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal > Page 8302 4. Separate the tabs (2) securing the fascia (3) to the bracket (1). 5. Remove the push pin (2) under the taillight (1) to the fascia (3). 6. Remove fascia (3) from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal > Page 8303 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia - Installation INSTALLATION 1. Install the fascia (3) to the vehicle and install the pushpin (2) at the taillight (1) to the body. 2. Clip the fascia (3) into the tabs (2) to the bracket (1). 3. Install the torx(R) screw (3) for the fascia top the wheel opening and then install the pop rivets (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal > Page 8304 4. Install the 6 push pins (1) to secure the fascia (2) to the body. 5. Close the hatch and check for fit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Reinforcement - Removal Rear Bumper Reinforcement: Service and Repair Rear Bumper Reinforcement - Removal REMOVAL 1. Remove rear fascia See: Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Removal. 2. Support bumper reinforcement (1) on a suitable lifting device. 3. Mark position of bolts (2) on frame rail to aid in installation. 4. Remove bolts (2) attaching rear bumper reinforcement (1) to frame rail. 5. Remove bumper reinforcement (1) from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Reinforcement - Removal > Page 8309 Rear Bumper Reinforcement: Service and Repair Rear Bumper Reinforcement - Installation INSTALLATION 1. Position rear bumper reinforcement (1) on vehicle. 2. Install bolts (2) attaching bumper reinforcement to frame rail. Use marks made previously to properly position bumper reinforcement. 3. Tighten bolts (2) to 28 Nm (250 in.lbs.). 4. Install rear fascia See: Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise Cowl Moulding / Trim: Customer Interest Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 8319 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 8320 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise Cowl Moulding / Trim: All Technical Service Bulletins Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 8326 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 8327 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8328 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 23-027-08 Date: 080906 Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8329 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8330 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-027-08 Date: 080906 Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8331 MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8332 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8333 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Inner Cover - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. 5. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 8336 Cowl Moulding / Trim: Service and Repair Cowl Panel Inner Cover - Installation INSTALLATION 1. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 2. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 3. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 8337 Cowl Moulding / Trim: Service and Repair Cowl Panel Outer Cover - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). 3. Remove the cowl top screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 8338 Cowl Moulding / Trim: Service and Repair Cowl Panel Outer Cover - Installation INSTALLATION 1. Position the cowl top screen (3). 2. Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > Recalls for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement Technical Service Bulletin # K07 Date: 110218 Recall - Front Door Wiring Harness Replacement February 2011 Dealer Service Instructions for: Safety Recall K07 Front Door Wiring Harnesses Safety Recall K07 Front Door Wiring Harnesses Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from November 01, 2007 through November 07, 2008 (MDH 110122 through 110723). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front door wiring harnesses on about 65,000 of the above vehicles may fatigue and break. Broken wires could interrupt the circuits for the side impact sensor(s) located inside the front doors. This could resulting in the illumination of the airbag warning lamp and loss of side crash sensing capability. Repair The right and left front door wiring harnesses must be replaced. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > Recalls for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8349 These special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > Recalls for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8350 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Open the hood. 2. Roll down both front door windows. 3. Disconnect and isolate the negative battery cable at the left shock tower. 4. Remove the front door window switch, grab handle cup, and release handle bezel (Figure 1). 5. Remove the front door panel (Figure 1). 6. Remove the front door inner window seal (Figure 1). 7. Separate the oval wiring harness grommet from the lower "A" pillar (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > Recalls for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8351 8. Disconnect the body electrical connectors from the front door wiring harness (Figure 2). 9. Remove the two door grommet retaining screws (Figure 2). 10. Remove the door speaker from the door and disconnect the electrical connector (Figure 2). 11. Open the access door and disconnect the door latch electrical connector (Figure 3). 12. Disconnect the remaining electrical connectors and remove the front door wiring harness from the vehicle (Figure 2). CAUTION: Note the wiring harness routing before removing the wiring harness from the door. The new wiring harness must be routed in the same location as the original wiring harness. 13. Place the new front door wiring harness into position on the door. 14. Connect the front door wiring harness connectors to the body electrical connectors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > Recalls for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8352 15. Snap the oval wiring harness grommet into the oval hole on the "A" pillar (Figure 1). 16. Place the door grommet into position and install the two retaining screws (Figure 1). 17. Connect the remaining electrical connectors to their respective modules/connectors (Figure 2). 18. Connect the door latch electrical connector and close the access door (Figure 3). 19. Connect the door speaker electrical connector and install the door speaker (Figure 4). 20. Install the front door inner window seal. 21. Install the front door panel. 22. Install the front door window switch, grab handle cup, and release handle bezel. 23. Repeat steps 4 through 22 on the other front door. 24. Connect the negative battery cable. 25. Using Mopar Total Clean or equivalent, clean both front door panels 26. On vehicles equipped with Express Window Up/Down (sales code JSC), perform Steps 27 through 30. 27. Connect the wiTECH to the vehicle. 28. Clear all Diagnostic Trouble Codes (DTC's). 29. Clear/Denormalize the door modules using the following procedures: a. Click on the "Miscellaneous Functions" tab. b. Select "Denormalize Window/Reset ECU" and follow the directions to clear/denormalize the door module memory. 30. Relearn/Normalize the door modules using the following procedure: a. Place the vehicle on a battery charger or have the engine running. b. Raise the front door glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the front door glass is fully closed. Continue to hold the window switch up for three seconds after the front door glass is fully closed. c. Lower the front door glass to the full-down position by pushing down (depress) the window switch to its second detent and hold the switch until the front door glass is fully open. Continue to hold the window switch down for three seconds after the front door glass is fully open. d. Check the operation of the express-up and express-down features. If the express-up feature does not work, repeat the procedure starting with Step 30b. e. Check that the front door glass reverses when in the express-up mode by holding a pen in the path of the glass. f. Repeat steps 30b. through 30e. on the other front door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > Recalls for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8353 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement Technical Service Bulletin # K07 Date: 110218 Recall - Front Door Wiring Harness Replacement February 2011 Dealer Service Instructions for: Safety Recall K07 Front Door Wiring Harnesses Safety Recall K07 Front Door Wiring Harnesses Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from November 01, 2007 through November 07, 2008 (MDH 110122 through 110723). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front door wiring harnesses on about 65,000 of the above vehicles may fatigue and break. Broken wires could interrupt the circuits for the side impact sensor(s) located inside the front doors. This could resulting in the illumination of the airbag warning lamp and loss of side crash sensing capability. Repair The right and left front door wiring harnesses must be replaced. Parts Information Special Tools Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8359 These special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8360 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Open the hood. 2. Roll down both front door windows. 3. Disconnect and isolate the negative battery cable at the left shock tower. 4. Remove the front door window switch, grab handle cup, and release handle bezel (Figure 1). 5. Remove the front door panel (Figure 1). 6. Remove the front door inner window seal (Figure 1). 7. Separate the oval wiring harness grommet from the lower "A" pillar (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8361 8. Disconnect the body electrical connectors from the front door wiring harness (Figure 2). 9. Remove the two door grommet retaining screws (Figure 2). 10. Remove the door speaker from the door and disconnect the electrical connector (Figure 2). 11. Open the access door and disconnect the door latch electrical connector (Figure 3). 12. Disconnect the remaining electrical connectors and remove the front door wiring harness from the vehicle (Figure 2). CAUTION: Note the wiring harness routing before removing the wiring harness from the door. The new wiring harness must be routed in the same location as the original wiring harness. 13. Place the new front door wiring harness into position on the door. 14. Connect the front door wiring harness connectors to the body electrical connectors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8362 15. Snap the oval wiring harness grommet into the oval hole on the "A" pillar (Figure 1). 16. Place the door grommet into position and install the two retaining screws (Figure 1). 17. Connect the remaining electrical connectors to their respective modules/connectors (Figure 2). 18. Connect the door latch electrical connector and close the access door (Figure 3). 19. Connect the door speaker electrical connector and install the door speaker (Figure 4). 20. Install the front door inner window seal. 21. Install the front door panel. 22. Install the front door window switch, grab handle cup, and release handle bezel. 23. Repeat steps 4 through 22 on the other front door. 24. Connect the negative battery cable. 25. Using Mopar Total Clean or equivalent, clean both front door panels 26. On vehicles equipped with Express Window Up/Down (sales code JSC), perform Steps 27 through 30. 27. Connect the wiTECH to the vehicle. 28. Clear all Diagnostic Trouble Codes (DTC's). 29. Clear/Denormalize the door modules using the following procedures: a. Click on the "Miscellaneous Functions" tab. b. Select "Denormalize Window/Reset ECU" and follow the directions to clear/denormalize the door module memory. 30. Relearn/Normalize the door modules using the following procedure: a. Place the vehicle on a battery charger or have the engine running. b. Raise the front door glass to the full-up position by pulling up on the window switch to its second detent and hold the switch until the front door glass is fully closed. Continue to hold the window switch up for three seconds after the front door glass is fully closed. c. Lower the front door glass to the full-down position by pushing down (depress) the window switch to its second detent and hold the switch until the front door glass is fully open. Continue to hold the window switch down for three seconds after the front door glass is fully open. d. Check the operation of the express-up and express-down features. If the express-up feature does not work, repeat the procedure starting with Step 30b. e. Check that the front door glass reverses when in the express-up mode by holding a pen in the path of the glass. f. Repeat steps 30b. through 30e. on the other front door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Stop: > K07 > Feb > 11 > Recall - Front Door Wiring Harness Replacement > Page 8363 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal Front Door Exterior Handle: Service and Repair Front Exterior Handle - Removal REMOVAL 1. Place the door glass in the full up position. 2. Remove door trim panel.See: Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect latch rods. 4. Remove fasteners (2) attaching door handle (1) to outer door panel. 5. Remove outside door handle from door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal > Page 8370 Front Door Exterior Handle: Service and Repair Front Exterior Handle - Installation INSTALLATION 1. Insert tip of handle (1) towards front of door through handle opening in door outer. 2. Pull handle at rear as if to open to swing handle into opening. 3. Install fasteners (2) into sheet metal and into rear side of door handle. 4. Tighten to 7 Nm (62 in. lbs.) 5. Install door trim panelSee: Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 6. Verify door handle operation. Adjust door latch as necessary. See: Front Door Latch/Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Interior Door Handle - Removal Front Door Interior Handle: Service and Repair Front Interior Door Handle - Removal REMOVAL 1. Remove trim panel from door.See: Front Door Panel/Service and Repair/Front Door Trim Panel Removal 2. Remove mounting fastener (1). 3. Remove the interior door handle from door module. 4. Disconnect the door handle cable (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Interior Door Handle - Removal > Page 8375 Front Door Interior Handle: Service and Repair Front Interior Door Handle - Installation INSTALLATION 1. Connect the interior handle cable (2) to the handle. 2. Position the handle to the door module ensuring that the handle is aligned correctly. 3. Install the mounting fastener (1). 4. Install the door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8384 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8385 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8391 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8392 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8393 Front Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8394 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8395 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8396 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 8397 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Door Hinge - Removal Front Door Hinge: Service and Repair Front Door Hinge - Removal REMOVAL 1. Remove front door from vehicle.See: Service and Repair/Front Door - Removal 2. Transfer door to bench. 3. Mark position of upper hinge (3) and lower hinge (4) on the upper A-pillar and lower A-pillar with a grease pencil or other suitable device to ease installation. 4. Remove bolts attaching hinge to door the upper A-pillar and lower A-pillar frame and remove the hinge. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Door Hinge - Removal > Page 8400 Front Door Hinge: Service and Repair Front Door Hinge - Installation INSTALLATION 1. If necessary, paint new door hinge prior to installation. 2. Loosely install bolts attaching hinge to lower A-pillar. 3. Align hinges to marks made previously and tighten all bolts. Tighten bolts to 28 Nm (21 ft. lbs.) torque. 4. Install the front door. See: Service and Repair/Front Door - Installation. 5. Verify door fit and operation. Adjust door hinge for proper door alignment, if necessary. See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENTS 1. Insert a suitable allen wrench through the elongated slot in door end frame and loosen bolt 1/2 to one full turn. 2. Cycle outside door handle twice. 3. Tighten adjusting screw. 4. Verify latch operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Latch - Removal Front Door Latch: Service and Repair Front Door Latch - Removal REMOVAL 1. Remove the door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 2. Remove the door module. See: Service and Repair/Front Door Carrier Plate Removal. 3. Remove the latch assembly from the rear of the door module by disengaging the clips. 4. Disconnect the latch cable (1) and rods (2) from the latch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Latch - Removal > Page 8406 Front Door Latch: Service and Repair Front Door Latch - Installation INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to reopen. 1. Position the latch assembly to the door module. 2. Connect the latch cable (1) and rods (2) to the latch assembly. 3. Snap the latch assembly into place onto the door module. 4. Install the door module. See: Service and Repair/Front Door Carrier Plate - Installation. 5. Install the door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly Front Door Panel: Customer Interest Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8415 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8416 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8417 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly Front Door Panel: All Technical Service Bulletins Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8423 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8424 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8425 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8426 Front Door Panel: By Symptom Technical Service Bulletin # 23-004-09 Date: 090304 Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8427 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8428 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8429 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-004-09 Date: 090304 Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8430 REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8431 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 8432 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel - Removal Front Door Panel: Service and Repair Front Door Trim Panel - Removal REMOVAL 1. Remove pull handle screw. 2. Remove screw from inside door handle. 3. Remove the power window controls. See: Sensors and Switches/Sensors and Switches - Windows and Glass/Power Window Switch/Service and Repair/Power Window Switch - Removal. 4. Using trim stick C-4755, pry trim panel from door (1). 5. Transfer trim panel (2) to bench Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel - Removal > Page 8435 Front Door Panel: Service and Repair Front Door Trim Panel - Installation INSTALLATION 1. Position door trim panel near to door. 2. Raise trim panel such that the backside of trim edge can be engaged with inner belt molding. 3. Press downward on top edge of trim panel while rotating bottom edge of panel towards door. 4. Position the locators at the top of the backside of the trim panel into the corresponding sheet metal holes ensuring fit. 5. Install the screw to the interior handle cover. 6. Install the screw to the pull handle. 7. Snap screw covers closed. 8. Install the power window controls. See: Sensors and Switches/Sensors and Switches - Windows and Glass/Power Window Switch/Service and Repair/Power Window Switch - Installation. 9. Close door window. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Latch Striker - Removal Front Door Striker: Service and Repair Door Latch Striker - Removal REMOVAL NOTE: Be sure to check for any shims between door latch striker and B-pillar. If any shims are found, they must be reinstalled with the new door latch striker to maintain proper door operation. 1. Mark outline of door latch striker on B-pillar to aid in installation. 2. Remove mounting fasteners attaching door latch striker to B-pillar. 3. Remove latch striker from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Latch Striker - Removal > Page 8440 Front Door Striker: Service and Repair Door Latch Striker - Installation INSTALLATION 1. Position door latch striker and any shims on vehicle. 2. Loosely install mounting fasteners attaching latch striker to B-pillar. 3. Align latch striker to marks on B-pillar made previously. 4. Tighten all fasteners. 5. Verify door fit and operation. Adjust door latch striker as necessary. See: Front Door Latch/Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal Front Door Window Glass: Service and Repair Front Door Glass - Removal REMOVAL 1. Remove door trim panel and re-install the window switches, if equipped. See: Front Door Panel/Service and Repair/Front Door Trim Panel Removal 2. Remove the interior window trim molding. 3. Remove the door speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Removal 4. Drill a hole large enough to get a small puch through into the carrier plate (3). 5. Lower glass to approximately mid position and line up the glass lift plates (1) with the holes (2 and 3). 6. Using a punch or equivalent, press tabs releasing glass from window regulator (2 and 3). 7. Remove glass from channel. 8. Raise glass (1) upward and out of the opening at top of door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal > Page 8445 Front Door Window Glass: Service and Repair Front Door Glass - Installation INSTALLATION 1. Lower glass (1) down and in the opening at top of door. 2. Slide glass downward making sure the glass holes properly lock into snaps (1). 3. Install the interior window trim molding. 4. Install the door speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Installation 5. Install door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Testing and Inspection Front Door Window Motor: Testing and Inspection WINDOW MOTOR 1. Remove door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 2. Connect positive (+) lead from a test battery to either of the two motor terminals. 3. Connect negative (-) lead from test battery to remaining motor terminal. 4. The motor should now rotate in one direction to either move window up or down. a. If window happens to already be in full UP position and motor is connected so as to move it in UP direction no movement will be observed. b. Likewise, motor connected to move window in DOWN direction no movement will be observed if window is already in full DOWN position. c. Reverse battery leads in 1 and 2 and window should now move. If window does not move, replace motor. 5. If window moved completely up or down, the test leads should be reversed one more time to complete a full window travel inspection. 6. If window does not move, check to make sure that it is free. 7. It is necessary that the window be free to slide up and down in the glass channels. If the window is not free to move up and down, the window lift motor will not be able to move the glass. 8. To determine if the glass is free, disconnect the regulator from the glass lift plate. Remove the two attaching screws, and slide the window up and down by hand. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal Front Door Window Motor: Service and Repair Window Regulator Motor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the electrical connector. 4. Remove the mounting fasteners and remove the motor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal > Page 8451 Front Door Window Motor: Service and Repair Window Regulator Motor - Installation INSTALLATION 1. Install the window motor and install the mounting fasteners. 2. Connect the electrical connector. 3. Install the door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal Front Door Window Regulator: Service and Repair Front Door Window Regulator - Removal REMOVAL 1. Remove door trim panel See: Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 2. Remove the door module assembly. See: Service and Repair/Front Door Carrier Plate - Removal. 3. Remove the power window lift motor See: Front Door Window Motor/Service and Repair/Window Regulator Motor - Removal. 4. Remove the regulator mounting fasteners. 5. Remove regulator from door module assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 8456 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Installation INSTALLATION 1. Position regulator on door module assembly and install mounting fasteners. 2. Install the power window motor. See: Front Door Window Motor/Service and Repair/Window Regulator Motor Installation. 3. Install the door module assembly. See: Service and Repair/Front Door Carrier Plate - Installation. 4. Install door trim panel. See: Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Exterior Door Handle - Removal Rear Door Exterior Handle: Service and Repair Rear Exterior Door Handle - Removal REMOVAL 1. Move the glass to the full up position. 2. Remove the door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Disconnect the link rod from the door handle. 4. Remove the mounting fasteners. 5. Remove the handle from the door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Exterior Door Handle - Removal > Page 8463 Rear Door Exterior Handle: Service and Repair Rear Exterior Door Handle - Installation INSTALLATION 1. Place the door handle into position in the door. 2. Install the mounting fasteners. 3. Connect the link rod to the door handle. 4. Install the door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 5. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Interior Door Handle - Removal Rear Door Interior Handle: Service and Repair Rear Interior Door Handle - Removal REMOVAL 1. Remove the door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Removal. 2. Remove the mounting fastener. 3. Disconnect the door handle cable from the interior handle. 4. Remove the handle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Interior Door Handle - Removal > Page 8468 Rear Door Interior Handle: Service and Repair Rear Interior Door Handle - Installation INSTALLATION 1. Connect the interior door handle cable. 2. Align the handle to the door module assembly. 3. Install the mounting fastener. 4. Install the door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 5. Verify proper operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8477 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8478 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8484 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8485 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8486 Rear Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8487 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8488 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8489 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8490 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal Rear Door Hinge: Service and Repair Rear Door Hinge - Removal REMOVAL 1. Remove the door See: Service and Repair/Rear Door - Removal. 2. Mark hinge attachment locations with a grease pencil or other suitable device on the B-pillar. 3. Remove the nuts and remove the hinges. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal > Page 8493 Rear Door Hinge: Service and Repair Rear Door Hinge - Installation INSTALLATION NOTE: If necessary, paint new door hinge prior to installation. 1. Loosely install bolts attaching hinge to lower B-pillar. 2. Align hinge to marks made previously and tighten bolts and nuts to 28 Nm (20 ft. lbs.). 3. Install the rear door See: Service and Repair/Rear Door - Installation. 4. Verify door fit and operation. Adjust door hinge for proper door alignment, as necessary. See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments ADJUSTMENTS 1. Insert a suitable allen wrench through the elongated slot in door end frame and loosen bolt 1/2 to one full turn. 2. Cycle outside door handle twice. 3. Tighten adjusting screw. 4. Verify latch operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal Rear Door Latch: Service and Repair Rear Door Latch - Removal REMOVAL 1. Remove the door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Removal. 2. Remove the door module assembly. 3. Remove the latch assembly from the rear of the door module by disengaging the clips. 4. Disconnect the latch cable and rods from the latch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal > Page 8499 Rear Door Latch: Service and Repair Rear Door Latch - Installation INSTALLATION 1. Position the latch assembly to the door module. 2. Connect the latch cable and rods to the latch assembly. 3. Snap the latch assembly into place onto the door module. 4. Install the door module. 5. Install the door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Installation. 6. Verify proper operation and adjust as necessary. See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly Rear Door Panel: Customer Interest Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8508 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8509 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Customer Interest for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8510 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly Rear Door Panel: All Technical Service Bulletins Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8516 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8517 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > 23-004-09 > Mar > 09 > Body - Doors Won't Lock/Unlock Properly > Page 8518 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8519 Rear Door Panel: By Symptom Technical Service Bulletin # 23-004-09 Date: 090304 Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8520 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8521 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8522 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-004-09 Date: 090304 Body - Doors Won't Lock/Unlock Properly NUMBER: 23-004-09 GROUP: Body DATE: March 4, 2009 SUBJECT: Doors Do Not Lock Or Unlock Properly When Using Power Door Lock System Or Remote Keyless Entry OVERVIEW: This bulletin involves modifying the door trim panel to assure the lock knob will not interfere with it. MODELS: 2009 (JC) Journey NOTE: This Bulletin applies to vehicles built before August 6, 2008 (MDH 0806XX). SYMPTOM/CONDITION: Some customers may experience difficulty locking or unlocking the doors when using the power door lock system or remote keyless entry transmitter. Mechanical interference between the lock knob & door trim panel may be preventing the keyless entry system form operating properly. DIAGNOSIS: If the customer experiences the Symptom/Condition perform the Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8523 REPAIR PROCEDURE: 1. Open Door. 2. Ensure doors are unlocked. 3. Using your hand wiggle the lock knobs. 4. Does the interior lock knob have wiggle room in the door panel? a. Yes >> This Service Bulletin does not apply, Further diagnosis is required. b. No >> Proceed to Step # 5 5. From inside the vehicle lock and unlock the door with the power door lock switch/FOB 1K. Watch the lock knob and door panel as switch is being activated. 6. Was there any interference detected between the lock knob and door panel? a. No >> This Service Bulletin does not apply, Further diagnosis is required. b. Yes >> Proceed to Step # 7 7. Remove door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect > TechCONNECT under: Service info > Body > Door - Front/Rear > Panel, Door Trim > Removal. 8. Use the FOBIK to lock and unlock the doors. 9. If the locking assembly work's properly then the lock knob has been rubbing the Door Trim Panel (Fig 1). 10. Inspect the three ribs inside the lock knob hole and verify how they look compared to (Fig 2) number two and three in. 11. Do the ribs match number two (Fig 2). a. Yes >> Continue the repair. b. No >> This Service Bulletin does not apply. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8524 12. Adjust the ribs angle accordingly with a square body file as shown in (Fig 3) to the desired angle shown in (Fig 2) number one. NOTE: Only modify the bottom portion of the rib(s) keeping top portion square to avoid rattle sounds. NOTE: Adjust lock knob ribs by filling from the inside to remove the lower rib edge. The tapered profile must be maintained to keep the lock knob from rattling in the door panel. 13. Install door trim panel. Refer to the detailed removal and installation procedures available in DealerConnect> TechCONNECT under: Service info > Body > Door-Front/Rear > Panel, Door Trim > Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Panel: > Page 8525 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Interior Window Trim Molding - Removal Rear Door Panel: Service and Repair Interior Window Trim Molding - Removal REMOVAL 1. Remove the door trim panel. See: Rear Door Trim Panel - Removal. 2. Remove the pushpin style retainers (3) from the front and rear of the interior window trim molding (2). 3. Remove the window trim molding from the rear door (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Interior Window Trim Molding - Removal > Page 8528 Rear Door Panel: Service and Repair Interior Window Trim Molding - Installation INSTALLATION 1. Position the interior window trim molding (2) to the door (1). 2. Install the pushpin style fasteners (3) to the front and rear of the molding. 3. Install the door trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Interior Window Trim Molding - Removal > Page 8529 Rear Door Panel: Service and Repair Rear Door Trim Panel - Removal REMOVAL 1. Remove fastener located in pull handle. 2. Remove fastener near inside door handle. 3. Using trim stick C-4755 or equivalent, gently pry upward on door trim panel (1) disengaging trim panel from door run. 4. Disconnect the power window switch if equipped. 5. Remove trim panel from door assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Interior Window Trim Molding - Removal > Page 8530 Rear Door Panel: Service and Repair Rear Door Trim Panel - Installation INSTALLATION 1. Install trim panel (1) to door assembly. 2. Connect the power window switch if equipped. 3. Install fastener located in pull handle. 4. Install fastener near inside door handle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Door Latch Striker - Removal Rear Door Striker: Service and Repair Door Latch Striker - Removal REMOVAL NOTE: Be sure to check for any shims between door latch striker and C-pillar. If any shims are found, they must be reinstalled with the new door latch striker to maintain proper door operation. 1. Mark outline of door latch striker on C-pillar. 2. Remove bolts attaching door latch striker to C-pillar. 3. Remove door latch striker from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Door Latch Striker - Removal > Page 8535 Rear Door Striker: Service and Repair Door Latch Striker - Installation INSTALLATION 1. Position door latch striker and any shims on vehicle. 2. Loosely install screws attaching latch striker to C-pillar. 3. Align latch striker to marks on C-pillar and tighten bolts to 20 Nm (14.8 ft. lbs.). 4. Verify door fit and operation. Adjust door latch striker as necessary. See: Rear Door Latch/Adjustments Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Outer Belt Molding - Removal Rear Door Window Glass Weatherstrip: Service and Repair Outer Belt Molding - Removal REMOVAL 1. Lower the window to the full down position. 2. Remove the rear door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove the front and rear mounting fasteners. 4. Remove the rear door belt molding (2) by carefully pulling up on the molding and remove from the rear door (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Outer Belt Molding - Removal > Page 8541 Rear Door Window Glass Weatherstrip: Service and Repair Outer Belt Molding - Installation INSTALLATION 1. Install the rear door belt molding (2) to the rear door (3). 2. Install the front and rear mounting fasteners. 3. Install the rear door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 4. Verify proper window operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Removal REMOVAL 1. Remove door trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Removal. 2. Remove the door module assembly. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove the power window lift motor. See: Front Door/Front Door Window Motor/Service and Repair/Window Regulator Motor - Removal 4. Remove the regulator mounting fasteners. 5. Remove regulator from door module assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 8546 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Installation INSTALLATION 1. Install regulator to door module assembly. 2. Install the regulator mounting fasteners. 3. Install the power window lift motor. See: Front Door/Front Door Window Motor/Service and Repair/Window Regulator Motor - Removal. 4. Install the door module assembly. See: Front Door/Front Door Window Motor/Service and Repair/Window Regulator Motor - Removal. 5. Install door trim panel. See: Front Door/Front Door Window Motor/Service and Repair/Window Regulator Motor - Removal. 6. Verify Proper operation of the window. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door - Removal Fuel Door: Service and Repair Fuel Fill Door - Removal REMOVAL 1. Open fuel filler door (2). 2. Remove the two torx screws (1). 3. Remove fuel filler door (2) from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door - Removal > Page 8551 Fuel Door: Service and Repair Fuel Fill Door - Installation INSTALLATION 1. Place fuel filler door (2) into position. 2. Install the two torx screws (1). 3. Ensure that door operates properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge - Removal Hood Hinge: Service and Repair Hood Hinge - Removal REMOVAL 1. Support hood on the side that requires hinge replacement. 2. Mark hinge attachment locations with a grease pencil or other suitable device to aid installation. 3. Remove cowl cover See: Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover - Removal See: Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Removal. 4. Remove bolts attaching hood to hinge. 5. Remove bolts attaching hood hinge to load beam inner and remove hinge from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge - Removal > Page 8557 Hood Hinge: Service and Repair Hood Hinge - Installation INSTALLATION 1. If necessary, paint new hinge before installation. 2. Place hinge in position on vehicle. 3. Install bolts to attach hood hinge to load beam inner. 4. Install bolts to attach hood to hinge. 5. Align all marks and secure bolts. 6. Tighten bolts to 28 Nm (20 ft. lbs.) torque. 7. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. 8. Install cowl cover See: Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover Installation See: Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Installation. 9. Verify hood latch operation. Adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch - Removal Hood Latch: Service and Repair Hood Latch - Removal REMOVAL 1. Release hood latch and open hood. 2. Support hood on prop rod. 3. Mark outline of hood latch on radiator support crossmember with a grease pencil or other suitable device to aid installation. 4. Remove nuts (1) attaching hood latch to upper radiator support crossmember. 5. Remove hood latch from vehicle. 6. Disengage remote release cable (2) from hood latch.See: Hood Latch Release Cable/Service and Repair/Hood Release Cable - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch - Removal > Page 8562 Hood Latch: Service and Repair Hood Latch - Installation INSTALLATION 1. Engage remote release cable into hood latch. 2. Position hood latch on vehicle. 3. Install nuts attaching hood latch onto upper radiator support crossmember. 4. Tighten nut to 28 Nm (20 ft.lbs.) torque. 5. Verify operation. Adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal Hood Latch Release Cable: Service and Repair Hood Release Cable - Removal REMOVAL 1. Remove left front cowl trim panel. 2. Remove screws (2) attaching hood release handle (1) to inner cowl panel. 3. Disconnect the hood release cable from the latch handle. 4. Disengage rubber grommet at lower dash panel. 5. Disengage push-in fastener (3) attaching hood release cable (4) to dash panel. 6. Remove hood latchSee: Hood Latch/Service and Repair/Hood Latch - Removal. 7. Release clips (2) attaching hood release cable to left inner frame rail. 8. Remove hood release cable (1) from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal > Page 8567 Hood Latch Release Cable: Service and Repair Hood Release Cable - Installation INSTALLATION 1. Route hood release cable (4) through hole in lower dash panel and along inner frame rail. 2. Engage rubber grommet to lower dash panel. 3. Engage push-in fastener (3) attaching hood release cable to lower dash panel. 4. Install screws attaching hood release cable handle (1) to inner cowl panel. 5. Tighten screws (2) to 1.8 Nm (16 in. lbs.) torque. 6. Install left front cowl trim panel. 7. Engage hood release cable into clips (2) along inner frame rail. 8. Install hood latch. See: Hood Latch/Service and Repair/Hood Latch - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8572 Hood Sensor/Switch (For Alarm): Diagrams Connector - (FRONT END MODULE) 2 WAY SWITCH-HOOD AJAR - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 8575 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (3) from the switch connector receptacle. 4. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 8578 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation SWITCH NOTE: Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit. 1. Position the hood ajar switch (1) above the hole in the mounting bracket (2). 2. Press the switch into the mounting hole until the integral switch latch tabs lock it into place. 3. Connect the harness connector (3) to the switch connector receptacle. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal Liftgate Window Glass: Service and Repair Liftgate Glass - Removal REMOVAL NOTE: Windshield removal shown, backlite similar. 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windows and Glass/Windshield/Service Precautions 2. Remove liftgate trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 3. Remove rear window wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Disconnect the heated backlite electrical connectors, if equipped. 5. Using a windshield cut-out wire or other suitable tool, separate the adhesive. 6. Carefully remove backlite. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8584 Liftgate Window Glass: Service and Repair Liftgate Glass - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The backlite fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the liftgate opening. Glass Preparation - Installing A Previously Installed Backlite 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windows and Glass/Windshield/Service Precautions 2. Level old bead of backlite adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. 3. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 4. Install the lower spacers (2) to the backlite approximately 25 mm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8585 5. Position backlite in center of liftgate opening and resting on the side and lower spacers. 6. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 7. Verify the backlite gap is parallel to with the liftgate opening. 8. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 9. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 10. Using a flash light, verify that glass primer is without damage. 11. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8586 12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 13. Allow primer to air dry for at least 10 minutes. 14. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Backlite 1. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 2. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. 3. Position backlite in center of liftgate opening and resting on the side and lower spacers. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8587 4. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 5. Verify the backlite gap is parallel to with the liftgate opening. 6. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 7. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 8. Apply primer to gluing surface at backlite seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8588 9. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 10. Allow primer to air dry for at least 10 minutes. 11. Using a flash light, verify that glass primer is without damage. Liftgate Opening Preparation NOTE: Windshield opening shown, liftgate opening similar. 1. Clean and vacuum liftgate opening. 2. Level old bead of liftgate opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8589 NOTE: Windshield opening shown, liftgate opening similar. 3. Clean and dry area of liftgate opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 5. Allow primer to air dry for at least 10 minutes. Backlite Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the backlite seal starting at bottom in center of the backlite. CAUTION: Always apply bead of adhesive to the backlite. Always install the backlite within 5 minutes after applying adhesive. 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 8590 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift backlite into place in the center of the liftgate opening and use the tape as a guide to aid installation of the backlite into the center of the cutout. 5. Carefully lay down the backlite and press on. CAUTION: It is no longer possible to move the backlite after installation. The backlite should never be pressed into place by more than one person, because the backlite can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install the rear wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 7. Install the liftgate trim panels. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Door Latch C1 (Liftgate) 2 Way Power Trunk / Liftgate Lock Actuator: Diagrams Liftgate Door Latch C1 (Liftgate) 2 Way Connector C1 - (LIFTGATE) 2 WAY LATCH-DOOR-LIFTGATE - (LIFTGATE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Door Latch C1 (Liftgate) 2 Way > Page 8596 Power Trunk / Liftgate Lock Actuator: Diagrams Liftgate Door Latch C2 (Liftgate) 3 Way Connector C2 - (LIFTGATE) 3 WAY LATCH-DOOR-LIFTGATE - (LIFTGATE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Release Solenoid - Removal Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Release Solenoid - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch assembly. See: Trunk / Liftgate Latch/Service and Repair/Liftgate Latch - Removal. 3. Remove the liftgate release solenoid. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Release Solenoid - Removal > Page 8599 Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Release Solenoid - Installation INSTALLATION 1. Install the liftgate latch. See: Trunk / Liftgate Latch/Service and Repair/Liftgate Latch Installation. 2. Install the liftgate trim panel. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal Trunk / Liftgate Hinge: Service and Repair Hinge - Removal REMOVAL NOTE: It is not necessary to remove the liftgate to replace one or both hinges. The hinges can be replaced one at a time. NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Place the liftgate in the full up position. 2. Support liftgate on a suitable lifting device. 3. Using a trim stick C-4755 or equivalent, remove the upper rear headliner trim. 4. Mark outline of hinge on the inside of liftgate to aid in installation. 5. Remove the upper hinge bolts (1). 6. Remove the lower hinge bolts (1). 7. Remove hinge from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal > Page 8604 Trunk / Liftgate Hinge: Service and Repair Hinge - Installation INSTALLATION 1. Position hinge to the vehicle. 2. Install the lower hinge bolts (1). Tighten the hinge bolts to 28 Nm (21 ft. lbs.). 3. Align the hinge to the previously made markings. 4. Install the upper hinge bolts (1). Tighten the hinge bolts to 28 Nm (21 ft. lbs.). 5. Install the upper rear headliner trim. 6. Close the liftgate and verify proper operation. See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Exterior Handle - Removal Trunk / Liftgate Handle: Service and Repair Liftgate Exterior Handle - Removal REMOVAL 1. Remove the liftgate trim panel. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 2. Remove the liftgate handle rear mounting nut. 3. Place the liftgate in the closed position. 4. Remove the mounting fasteners on the front of the liftgate handle. 5. Disconnect the liftgate handle latch cable. 6. Disconnect the electrical connectors and remove the liftgate handle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Exterior Handle - Removal > Page 8609 Trunk / Liftgate Handle: Service and Repair Liftgate Exterior Handle - Installation INSTALLATION 1. Connect the liftgate handle latch cable. 2. Connect electrical connectors and seat the liftgate handle into position. 3. Install the front liftgate handle fasteners. 4. Place the liftgate in the up position. 5. Install the rear liftgate handle fastener. 6. Install the liftgate trim panel. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel - Removal REMOVAL 1. Remove the left and right side trim panels. 2. Using a trim stick C-4829A or equivalent, separate the pushpin fasteners and remove the upper trim panel. 3. Remove the two lower screws. 4. Remove the lower trim panel and disconnect the electrical connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 8614 Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel - Installation INSTALLATION 1. Connect the electrical connector and install the lower trim panel. 2. Install the two lower screws. 3. Install the left and right side trim panels. 4. Position the upper trim into place and seat the push pin fasteners fully. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch - Removal Trunk / Liftgate Latch: Service and Repair Liftgate Latch - Removal REMOVAL 1. Remove the liftgate trim panel. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 2. Disconnect the electrical connector (2) from the latch (3). 3. Disconnect the liftgate latch cable (1). 4. Lower the liftgate to mid position and remove the latch mounting bolts. 5. Remove the liftgate latch from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch - Removal > Page 8619 Trunk / Liftgate Latch: Service and Repair Liftgate Latch - Installation INSTALLATION 1. Position the liftgate latch to the liftgate. 2. Install the mounting fasteners. Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Connect the liftgate latch cable. 4. Connect the electrical connector to the latch. 5. Install the liftgate trim panel. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 6. Close the liftgate and verify proper operation. See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal Trunk / Liftgate Shock / Support: Service and Repair Gas Prop - Removal REMOVAL 1. Open liftgate. 2. Using a small flat bladed tool or equivalent, release the retaining clips while pulling the ball socket away from the ball stud. 3. Remove the gas prop-rod lock caps. 4. Remove the support cylinder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal > Page 8624 Trunk / Liftgate Shock / Support: Service and Repair Gas Prop - Installation INSTALLATION 1. Make sure the retaining clips are seated into the ball socket (2) fully. 2. Install the support cylinder over the ball studs with the thin end connected to the liftgate and the retaining clips snapping into place. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Adjustments Trunk / Liftgate Striker: Adjustments ADJUSTMENT 1. Using a grease pencil or equivalent, mark the position of the striker to aid in adjustment. 2. Loosen the striker bolts. 3. Change the striker position to adjust the lower liftgate gap and flush measurement. 4. Tighten the bolts to 28 Nm (21 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Liftgate Latch Striker - Removal Trunk / Liftgate Striker: Service and Repair Liftgate Latch Striker - Removal REMOVAL 1. Open the liftgate. 2. Remove screws attaching liftgate striker to floor pan (1) and remove the striker. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Nameplate - Removal Body Emblem: Service and Repair Nameplate - Removal REMOVAL NOTE: Exterior nameplates are attached to body panels with adhesive tape. 1. Apply a length of masking tape on the body, parallel to the top edge of the nameplate to use as a guide, if necessary. 2. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun. Do not exceed 52°C (120°F) when heating emblem. 3. Insert a plastic trim stick or a hard wood wedge behind the emblem to separate the adhesive backing from the body. 4. Clean adhesive residue from body with MOPAR(R) Super Kleen solvent or equivalent. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Nameplate - Removal > Page 8635 Body Emblem: Service and Repair Nameplate - Installation INSTALLATION 1. Remove carrier from adhesive tape on back of emblem. 2. Position emblem properly on body. 3. Press emblem firmly to body with palm of hand. 4. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52°C (120°F) when heating emblem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise Cowl Moulding / Trim: Customer Interest Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 8644 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 8645 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body Cowl Panel Gap At Windshield/Wind Noise Cowl Moulding / Trim: All Technical Service Bulletins Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body Cowl Panel Gap At Windshield/Wind Noise > Page 8651 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body Cowl Panel Gap At Windshield/Wind Noise > Page 8652 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8653 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 23-027-08 Date: 080906 Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8654 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8655 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-027-08 Date: 080906 Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8656 MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8657 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8658 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Inner Cover - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. 5. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 8661 Cowl Moulding / Trim: Service and Repair Cowl Panel Inner Cover - Installation INSTALLATION 1. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 2. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 3. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 8662 Cowl Moulding / Trim: Service and Repair Cowl Panel Outer Cover - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). 3. Remove the cowl top screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 8663 Cowl Moulding / Trim: Service and Repair Cowl Panel Outer Cover - Installation INSTALLATION 1. Position the cowl top screen (3). 2. Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Cladding - Removal Lower Side Moulding / Trim: Service and Repair Body Cladding - Removal REMOVAL 1. Warm the effected adhesive type molding and body metal to approximately 38°C (100°F) using a suitable heat lamp or heat gun. 2. Pull stick-on molding from painted surface. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Cladding - Removal > Page 8668 Lower Side Moulding / Trim: Service and Repair Body Cladding - Installation INSTALLATION 1. Clean body surface with MOPAR(R) Super Kleen solvent or equivalent. Wipe surface dry with lint free cloth. 2. Remove protective cover from tape on back of molding. Apply molding to body below the masking tape guide. 3. Remove masking tape guide and firmly press molding to body surface to assure adhesion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Splash Shield - Removal Front Fender Liner: Service and Repair Splash Shield - Removal REMOVAL NOTE: The front splash shields are a two piece assembly. 1. Remove the appropriate front wheel. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Removal 2. Remove push pins. 3. Remove fasteners. 4. Remove splash shield from wheel well. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Splash Shield - Removal > Page 8675 Front Fender Liner: Service and Repair Splash Shield - Installation INSTALLATION 1. Place splash shield up to wheelhouse opening. 2. Install push pins. 3. Install fasteners. 4. Install the front wheel. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Splash Shield - Removal Rear Fender Liner: Service and Repair Splash Shield - Removal REMOVAL 1. Remove the appropriate rear wheel. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Removal. 2. Remove push pins. 3. Remove fasteners. 4. Remove splash shield from wheel well. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Splash Shield - Removal > Page 8681 Rear Fender Liner: Service and Repair Splash Shield - Installation INSTALLATION 1. Place splash shield up to wheelhouse opening. 2. Install push pins. 3. Install fasteners. 4. Install the rear wheel. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise Rear Cross-Member: Customer Interest Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 8692 b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > Customer Interest for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension - Rear Suspension Squeaking Noise > Page 8693 CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension Rear Suspension Squeaking Noise Rear Cross-Member: All Technical Service Bulletins Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension Rear Suspension Squeaking Noise > Page 8699 b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > 02-004-08 > Jul > 08 > Suspension Rear Suspension Squeaking Noise > Page 8700 CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 8701 Rear Cross-Member: By Symptom Technical Service Bulletin # 02-004-08 Date: 080731 Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 8702 a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 8703 3. Remove the brackets. CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 02-004-08 Date: 080731 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 8704 Suspension - Rear Suspension Squeaking Noise NUMBER: 02-004-08 GROUP: Suspension DATE: July 31, 2008 SUBJECT: Rear Suspension Squeak OVERVIEW: This bulletin involves inspection and adjustment of the rear suspension to correct park brake cable clamp screw head interference with the rear crossmember right front mounting bolt washer. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 and April 15, 2008 (MDH0102XX > MDH0415XX). SYMPTOM/CONDITION: Vehicle operator may complain of a squeak or creak sound heard from the rear of the vehicle while driving over bumps. DIAGNOSIS: 1. Raise and support the vehicle. 2. Locate the park brake cable clamp screw and rear crossmember mounting bolt washer on both the right and left front side of the crossmember (Fig. 1). 3. Check for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer (Fig. 1). 4. Is the gap 3 mm (0.118 in.) or greater? a. Yes >>> Perform rear crossmember mounting bolt torque verification Repair Procedure. b. No >>> Perform rear crossmember centering and adjustment Repair Procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 8705 SPECIAL TOOLS/EQUIPMENT REQUIRED: TORQUE VERIFICATION REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. 4. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 5. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 6. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 7. Install the mounting screws securing the crossmember reinforcement brackets to the body. 8. Torque the screws to 55 N.m (41 ft. lbs.). 9. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 10. Lower the vehicle. REAR CROSSMEMBER CENTERING AND ADJUSTMENT REPAIR PROCEDURE: 1. Remove the two mounting screws securing each crossmember reinforcement bracket (one each side of vehicle) to the body (Fig. 2). 2. Remove the mounting nuts securing the crossmember reinforcement brackets to the crossmember rear mounting bolts (Fig. 2). 3. Remove the brackets. CAUTION: Do not remove the four mounting bolts in the next step. Just Loosen them. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Cross-Member: > Page 8706 4. Loosen the four mounting bolts securing the crossmember to the body to allow enough movement for repositioning of the crossmember (Fig. 2). 5. With the mounting bolts loose, reposition the crossmember to allow for a minimum of 3 mm (0.118 in.) clearance between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. If available, place a 3 mm (0.118 in.) mechanical spacer between the park brake cable clamp screw head and the rear crossmember mounting bolt washer. NOTE: The next step is critical in securing the crossmember to the body and must be done prior to securing the rear fasteners. 6. Once the crossmember position has been adjusted to allow for 3mm (0.118 in.) or more clearance on both sides, tighten the forward (front) rear crossmember mounting bolts first. NOTE: If a mechanical spacer is used, be sure the mechanical spacer is in place to maintain proper clearance while securing the front fasteners. 7. Torque the forward (front) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 8. Torque the aft (rear) rear crossmember mounting bolts to 95 N.m (70 ft. lbs.). 9. Remove the 3 mm (0.118 in.) spacer if used. 10. Position the crossmember reinforcement brackets (one each side of vehicle) over the crossmember rear mounting bolt head-studs and install the mounting nuts, but do not tighten at this time. 11. Install the mounting screws securing the crossmember reinforcement brackets to the body. 12. Torque the screws to 55 N.m (41 ft. lbs.). 13. Torque the mounting nuts securing the reinforcement brackets to the rear crossmember mounting bolts to 50 N.m (37 ft. lbs.). 14. Lower the vehicle. 15. Perform rear wheel alignment as necessary. Refer to the detailed procedures available in DealerCONNECT > TechCONNECT under: Service Info > 02 - Front Suspension > Wheel Alignment > Standard Procedure > WHEEL ALIGNMENT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair > Wheelhouse Brace - Removal Structural Brace: Service and Repair Wheelhouse Brace - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair > Wheelhouse Brace - Removal > Page 8711 5. Remove the eight mounting bolts (four each side) (1) securing the wheel house brace to the strut towers. 6. Remove the wheelhouse brace (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair > Wheelhouse Brace - Removal > Page 8712 Structural Brace: Service and Repair Wheelhouse Brace - Installation INSTALLATION 1. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 Nm (35 ft. lbs.). 2. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 3. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair > Wheelhouse Brace - Removal > Page 8713 4. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Service and Repair Trailer Adapter Kit: Service and Repair TRAILER TOW HARNESS INSTALLATION 1. Remove the push pin fasteners (2) and separate the rear tail lamp assemblies (1). 2. Disconnect the tail lamp electrical connectors (2 and 3). 3. Connect the harness (2) to the left side tail lamp electrical connectors (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Service and Repair > Page 8717 4. Position the harness (1) through the tail lamp opening and down the side of the fender. 5. Secure the support clips (2) to the body seem. 6. Position the harness (1) over the exhaust and fasten the push pin fasteners (2) to the under side of the rear bumper in the existing holes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Service and Repair > Page 8718 7. Position the harness (1) up the right side of the vehicle to the right tail lamp opening and secure the clips (2) to the body seem. 8. Connect the harness (1) to the right side tail lamp electrical connectors (2). 9. Connect the tail lamp electrical connectors (2 and 3) to the tail lamp assemblies (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Service and Repair > Page 8719 10. Install tail lamps assemblies (1) and install the push pin fasteners (2) fully. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8724 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8725 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8726 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Trailer Towing Relay: Diagrams Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8729 Trailer Towing Relay: Diagrams Right Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8730 Trailer Towing Relay: Diagrams Left Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8731 Trailer Towing Relay: Diagrams Right Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional trailer tow preparation package have four trailer tow relays, one each for the trailer tow stop/turn right and left and one each for the trailer stop lamp right and left. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are included with the trailer tow preparation wire harness that is shipped loose in the glove box for customer or dealer installation at the rear of the vehicle. A trailer tow stop/turn relay is located behind the rear fascia below each outer tail lamp, while a trailer stop lamp relay is located behind the rear fascia below each outboard end of the rear bumper reinforcement. Each relay and connector is wrapped within an isolator envelope for sound deadening and anti-rattle protection. Refer to the appropriate wiring information for specific relay cavity assignment information. Any of the trailer tow relays cannot be adjusted or repaired and, if ineffective or damaged, the affected unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 8734 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Totally Integrated Power Module (TIPM) to the tail lamps to control a high current output to the trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right trailer tow stop/turn signal pins of the 4-way trailer tow connector at all times. The common feed terminals of both the left and right trailer tow stop relays is connected to the normally closed (87A) terminal of their respective left or right trailer tow stop/turn relay at all times. - Coil Ground Terminal (85) - The coil ground terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. The coil ground terminals of both the left and right trailer tow stop relays are connected to the stop lamp control circuit from the TIPM at all times. - Coil Battery Terminal (86) - The coil battery terminal of both the left and right trailer tow stop/turn relays is connected to a path to ground at all times. The coil battery terminal of both the left and right trailer tow stop relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. - Normally Open Terminal (87) - The normally open terminal of both the left and right trailer tow stop/turn relays is connected to the stop lamp control circuit from the TIPM whenever that relay is energized. The normally open terminal of both the left and right trailer tow stop relays is connected to a path to ground whenever that relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal of both the left and right trailer tow stop/turn relays is connected are connected to the common supply (30) terminal of their respective left or right trailer tow stop relay whenever the relay is de-energized. The normally closed terminal of both the left and right trailer tow stop relays is not connected to any circuit in this application. The trailer tow relays and the hard wired circuits for the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that provide some features of the trailer tow turn and stop lamp lighting system. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to trailer tow turn and stop lamp lighting operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal Trailer Towing Relay: Service and Repair Trailer Tow Relay - Removal REMOVAL TRAILER TOW STOP/TURN RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Removal 3. Disengage the left or right trailer tow stop/turn relay and connector from the isolator envelope (3) secured to the trailer tow wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Pull the relay straight out from the wire harness connector. TRAILER TOW STOP LAMP RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Removal 3. Disengage the left or right trailer tow stop lamp relay and connector from the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Pull the relay straight out from the wire harness connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal > Page 8737 Trailer Towing Relay: Service and Repair Trailer Tow Relay - Installation INSTALLATION TRAILER TOW STOP/TURN RELAYS 1. Align the terminals of the left or right trailer tow stop/turn relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (3) secured to the wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Reinstall the rear fascia onto the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Installation. 5. Reconnect the battery negative cable. TRAILER TOW STOP LAMP RELAYS 1. Align the terminals of the left or right trailer tow stop lamp relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Reinstall the rear fascia onto the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest - Removal Arm Rest: Service and Repair Armrest - Removal REMOVAL 1. Position the 40 split seat with back folded flat, to the full forward position. 2. Partially remove the armrest side shield and remove the mounting fastener. 3. With the armrest folded down, remove the two mounting fasteners located on the inside of the armrest bracket. 4. Remove the armrest from the vehicle. NOTE: Only perform the following steps if the cover or foam replacement is required. 5. Remove the armrest plastic cover, by carefully prying up until the retainers disengage. 6. If equipped, remove the headrest. 7. Remove the headrest sleeves, if equipped. 8. Carefully pull the seat cover off of the armrest and remove the cover. 9. Remove the foam as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest - Removal > Page 8743 Arm Rest: Service and Repair Armrest - Installation INSTALLATION 1. Install the foam, if required. 2. Carefully install the seat cover to the armrest. 3. If equipped, install the headrest sleeves to the armrest. 4. Install the headrest, if equipped. 5. Install the armrest plastic cover, ensuring the retainers engage. 6. Position the armrest to the vehicle. 7. With the armrest folded down, install the two mounting fasteners located on the inside of the armrest bracket. Tighten to 40 N-m (29 ft. lbs.). 8. Install the outboard armrest mounting fastener. Tighten to 30 N-m (22 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet - Removal Carpet: Service and Repair Carpet - Removal REMOVAL 1. Remove door sill trim. See: Scuff Plate/Service and Repair/Scuff Plate - Removal 2. Remove front seats. See: Seats/Service and Repair/Seats, Front/Seat - Removal. 3. Remove the second row seats. See: Seats/Service and Repair/Seats, Front/Seat - Removal 4. Remove the third row seats, if equipped. See: Seats/Service and Repair/Seats, Front/Seat - Removal. 5. Remove B-pillar trim panels as necessary to clear carpet. 6. Remove cowl trim panels. See: Trim Panel/Service and Repair/Cowl Trim Panel - Removal 7. Remove center console.See: Console/Service and Repair/Center Console - Removal 8. Remove the rear storage bin. See: Utility Storage Compartment/Service and Repair/Rear Storage Bin - Removal. 9. Remove the rear storage box. See: Utility Storage Compartment/Service and Repair/Rear Storage Box - Removal. 10. Pull carpet from behind brake pedal, accelerator pedal and remove the front left carpet (5). 11. Pull carpet from behind the HVAC and remove the front right carpet (2). 12. Remove the rear carpet from the vehicle (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet - Removal > Page 8748 Carpet: Service and Repair Carpet - Installation INSTALLATION 1. Install the rear carpet to the vehicle (3). 2. Install the front right carpet (2) and push the carpet behind the HVAC. 3. Install the front left carpet (5) and push the carpet behind brake pedal and accelerator pedal. 4. Install the rear storage box. See: Utility Storage Compartment/Service and Repair/Rear Storage Box - Installation. 5. Install the rear storage bin. See: Utility Storage Compartment/Service and Repair/Rear Storage Bin - Installation. 6. Install center console. See: Console/Service and Repair/Center Console - Installation. 7. Install cowl trim panels. See: Trim Panel/Service and Repair/Cowl Trim Panel - Installation. 8. Install B-pillar trim panels as necessary to clear carpet. 9. Install the third row seats, if equipped. See: Seats/Service and Repair/Seats, Front/Seat - Installation. 10. Install the second row seats. See: Seats/Service and Repair/Seats, Front/Seat - Installation. 11. Install front seats. See: Seats/Service and Repair/Seats, Front/Seat - Installation 12. Install door sill trim. See: Scuff Plate/Service and Repair/Scuff Plate - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched Console: Customer Interest Interior - Sunglass Holder Will Not Stay Latched NUMBER: 23-004-10 GROUP: Body DATE: February 27, 2010 SUBJECT: Sunglass Holder Will Not Stay Latched OVERVIEW: If the overhead console endures excessive heat the bezel may warp and the sunglass holder door will not stay latched in the closed position. Dealers are required to replace the bezel and follower arm which guides the sunglass holder door. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles built before March 27, 2009 (MDH0327XX). SYMPTOM/CONDITION: The customer may experience the sunglass holder door unlatching and not return returning to the closed position in high heat conditions. DIAGNOSIS: Inspect the sunglass holder door, if it does not return to the closed position, perform the Repair Procedure. PARTS REQUIRED: NOTE: Each kit will include two follower arms but only one is needed to perform the repair procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the overhead console assembly. Refer to the detailed removal procedures available in: DealerConnect > TechCONNECT under: Service Info > Electrical > Message Systems > Overhead Console> Removal > Console Assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8757 2. Remove the sunroof switch (If equipped) by flexing the 4 retaining tabs. Transfer the sunroof switch to the new console bezel by snapping it into the retaining tabs (Fig 1). 3. Remove the 4 fasteners that secure the sunglass holder bin assembly to the console bezel and remove the bin assembly (Fig. 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8758 4. Open the sunglass holder and remove the follower arm from the sunglass bin assembly by squeezing the 2 locking tabs on the outer side of the bin (Fig. 3). Discard the old follower arm and replace with the new one provided in the kit. 5. With the sunglass holder open, align the center pin and snap the arm into the bin housing. Check that the follower arm is properly engaged into the housing by rotating it (Fig. 4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8759 6. Place the sunglass bin housing onto the locators on the new console bezel and fasten with 4 screws (Fig. 5). 7. Hold the console as it would be positioned in the vehicle and test the function of the latch mechanism ensuring that all positions can be achieved. 8. Remove the lamp assembly from the console bezel by unsnapping the 2 locking tabs at the forward edge of the console (Fig. 6). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8760 9. Transfer the lamp assembly to the new bezel by aligning the locator pins and snapping into place (Fig. 7). 10. Install the overhead console assembly. Refer to the detailed installation procedures available in: DealerConnect > TechCONNECT under: Service Info > Electrical > Message Systems > Overhead Console > Installation > Console Assembly. 11. Return the vehicle to the customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched Console: All Technical Service Bulletins Interior - Sunglass Holder Will Not Stay Latched NUMBER: 23-004-10 GROUP: Body DATE: February 27, 2010 SUBJECT: Sunglass Holder Will Not Stay Latched OVERVIEW: If the overhead console endures excessive heat the bezel may warp and the sunglass holder door will not stay latched in the closed position. Dealers are required to replace the bezel and follower arm which guides the sunglass holder door. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles built before March 27, 2009 (MDH0327XX). SYMPTOM/CONDITION: The customer may experience the sunglass holder door unlatching and not return returning to the closed position in high heat conditions. DIAGNOSIS: Inspect the sunglass holder door, if it does not return to the closed position, perform the Repair Procedure. PARTS REQUIRED: NOTE: Each kit will include two follower arms but only one is needed to perform the repair procedure. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the overhead console assembly. Refer to the detailed removal procedures available in: DealerConnect > TechCONNECT under: Service Info > Electrical > Message Systems > Overhead Console> Removal > Console Assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8766 2. Remove the sunroof switch (If equipped) by flexing the 4 retaining tabs. Transfer the sunroof switch to the new console bezel by snapping it into the retaining tabs (Fig 1). 3. Remove the 4 fasteners that secure the sunglass holder bin assembly to the console bezel and remove the bin assembly (Fig. 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8767 4. Open the sunglass holder and remove the follower arm from the sunglass bin assembly by squeezing the 2 locking tabs on the outer side of the bin (Fig. 3). Discard the old follower arm and replace with the new one provided in the kit. 5. With the sunglass holder open, align the center pin and snap the arm into the bin housing. Check that the follower arm is properly engaged into the housing by rotating it (Fig. 4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8768 6. Place the sunglass bin housing onto the locators on the new console bezel and fasten with 4 screws (Fig. 5). 7. Hold the console as it would be positioned in the vehicle and test the function of the latch mechanism ensuring that all positions can be achieved. 8. Remove the lamp assembly from the console bezel by unsnapping the 2 locking tabs at the forward edge of the console (Fig. 6). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-004-10 > Feb > 10 > Interior - Sunglass Holder Will Not Stay Latched > Page 8769 9. Transfer the lamp assembly to the new bezel by aligning the locator pins and snapping into place (Fig. 7). 10. Install the overhead console assembly. Refer to the detailed installation procedures available in: DealerConnect > TechCONNECT under: Service Info > Electrical > Message Systems > Overhead Console > Installation > Console Assembly. 11. Return the vehicle to the customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 8770 Console: Description and Operation DESCRIPTION There are two different style's of overhead console (1) available on this vehicle, High line and Mid or Low line. All overhead consoles are equipped with a sunglasses storage bin (2) and two reading and courtesy lamps (4). On High line models, the reading lamps are a Light Emitting Diode (LED) multi directional design, and on the Mid or Low line design the lamps are fixed with a replaceable incandescent bulb. The sunglasses storage bin also has a conversation mirror that is visible when the bin is locked in the partial open position. On vehicles equipped with a power sunroof, the sunroof switch (5) is located behind the sunglasses bin. On vehicles equipped with automatic climate control an infrared temperature sensor (3) is located between the reading and courtesy lamps. Both overhead console designs are mounted with six snap clips into a molded plastic retainer bracket located above the headliner to provide secure overhead console attachment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal Console: Service and Repair Center Console - Removal REMOVAL 1. Remove the shifter bezel and shifter knob. 2. Place the parking brake handle (6) in the up position. 3. Remove the side mounting fasteners (1). 4. Open the console lid (3) and remove the four mounting fasteners (2). 5. Carefully pry up on the front of the center console until the retainers disengage from the instrument panel center console (5). 6. Disconnect the electrical connector (4) at the back of the center floor console. 7. Remove the center floor console from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal > Page 8773 Console: Service and Repair Center Console - Installation INSTALLATION 1. Install the center floor console into position to the vehicle. 2. Connect the electrical connector (4) at the back of the center floor console. 3. Carefully depress the front of the center console until the retainers engage to the instrument panel center console (5). 4. Install the four mounting fasteners (2) located in the storage bin area. 5. Install the side mounting fasteners (1). 6. Install the shifter bezel and shifter knob. 7. Lower the parking brake handle (6). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal > Page 8774 Console: Service and Repair Overhead Console - Removal Console Assembly CONSOLE ASSEMBLY 1. Disconnect and isolate the battery negative cable. 2. Using your fingertips, grasp the sides of the overhead console (1) and pull straight down evenly to disengage the snap clips from the mounting bracket. 3. Lower the overhead console (5) far enough to access the wire harness connectors. 4. If equipped, disconnect the courtesy lamps (1), infrared temperature sensor (2) and power sunroof switch (4) electrical connectors. 5. Remove the overhead console assembly from the vehicle. Sunglasses Bin SUNGLASSES BIN Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal > Page 8775 1. Remove the overhead console (5), See: . 2. Remove the four fasteners (3) that secure the sunglasses bin (6) to the console. 3. Remove the bin from the console. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal > Page 8776 Console: Service and Repair Overhead Console - Installation Console Assembly CONSOLE ASSEMBLY 1. Position the overhead console (5) in the vehicle near the headliner assembly. 2. If equipped, connect the courtesy lamps (1), infrared temperature sensor (2) and power sunroof switch (4) electrical connectors. 3. Position the overhead console so that the six retaining clips are lined up properly with the bracket. 4. Applying pressure to the overhead console (1), push straight up evenly to engage the snap clips into the mounting bracket. 5. Connect the battery negative cable. Sunglasses Bin SUNGLASSES BIN Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal > Page 8777 1. Install the sunglasses bin (6) into the overhead console (5). 2. Install the four fasteners (3) that secure the bin to the console. 3. Install the overhead console, See: . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal Glove Compartment: Service and Repair Glove Box Door Latch - Removal REMOVAL 1. Open the glove box. 2. Remove the three glove box latch screws. 3. Separate the latch from the glove box assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal > Page 8782 Glove Compartment: Service and Repair Glove Box Door Latch - Installation INSTALLATION 1. Install the latch onto the glove box assembly. 2. Install the glove box latch screws. 3. Close glove box door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal > Page 8783 Glove Compartment: Service and Repair Instrument Panel Glove Box - Removal REMOVAL 1. Open glove box. 2. Push in on sides of glove box bin and lower door. 3. Pivot glove box downward and disengage hinge hooks from instrument panel. 4. Remove glove box. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal > Page 8784 Glove Compartment: Service and Repair Instrument Panel Glove Box - Installation INSTALLATION 1. Place glove box in position. 2. Engage hinge hooks into instrument panel and pivot glove box upward. 3. Push in sides of glove box bin and snap glove box assembly into instrument panel. 4. Close glove box door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal Headliner: Service and Repair Headliner - Removal REMOVAL NOTE: Do not remove the headliner from the vehicle, unless replacing with a new headliner or it is absolutely necessary. 1. Remove the sun visors by removing the mounting fasteners and disconnect the electrical connector, if equipped. 2. Remove the sun visor support mounting fasteners and remove the support from the headliner. 3. Remove the A-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Removal. 4. Remove the B-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 5. Remove the C-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal 6. Remove the D-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 7. Remove the overhead console. See: Console/Service and Repair/Overhead Console - Removal. 8. Remove the header trim panel by carefully pulling down on the trim disengaging the retainers. 9. Remove the mounting fasteners and remove the grab handles and coat hooks. 10. Remove the left quarter trim panel. See: Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 11. Remove the seat belt mounting bracket from the right D-pillar. 12. Lower the first and second row seats as far as possible removing the headrests as necessary. 13. Disconnect electrical connectors. 14. Remove the pushpin retainers at the rear of the headliner. 15. Carefully disengage retaining clips and lower headliner. 16. With the help of an assistant(s), remove the headliner from the vehicle through the lift gate opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 8789 Headliner: Service and Repair Headliner - Installation INSTALLATION 1. With the help of an assistant(s), carefully install the headliner into the vehicle through the rear liftgate opening. Do not over flex the headliner and be carefully not to crack or mar the headliner. 2. Raise the headliner into position and engage the retainers. 3. Connect the electrical connectors. 4. Install the grab handles and coat hooks. Install the mounting fasteners. 5. Install the overhead console. See: Console/Service and Repair/Overhead Console - Installation. 6. Install the D-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 7. Install the C-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 8. Install the B-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 9. Install the A-pillar trim panel. See: Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Installation. 10. Install the quarter trim panel to the vehicle. See: Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 11. Install the sun visor support and mounting fasteners. 12. Install the sun visors and mounting fasteners. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Scuff Plate - Removal Scuff Plate: Service and Repair Scuff Plate - Removal Door Sill REMOVAL 1. Using trim stick C-4755 disengage clips holding door sill scuff panel and to door sill. 2. Starting at forward end of door sill scuff panel, pull upward on sill scuff panel in order to disengage clips attaching sill scuff panel to door opening flange. 3. Remove door sill scuff panel from vehicle. Liftgate Sill REMOVAL 1. Open the liftgate. 2. Using trim stick C-4755, carefully pry the liftgate sill plate out disengaging the retaining clips. 3. Remove the liftgate sill plate from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Scuff Plate - Removal > Page 8794 Scuff Plate: Service and Repair Scuff Plate - Installation Door Sill INSTALLATION 1. Place door sill trim panel into position. 2. Ensure plastic retaining nut is installed. 3. Pushing downward on sill trim panel to engage tabs and attaching clips to the door sill. Liftgate Sill INSTALLATION 1. Position the liftgate sill plate into the vehicle. 2. Firmly press the sill plate downward securing the retaining clips. 3. Close the liftgate. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal Sun Visor: Service and Repair Visor Support - Removal REMOVAL 1. Disengage sun visor from center support. 2. Remove mounting fasteners attaching support to roof header, 3. Remove support from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal > Page 8799 Sun Visor: Service and Repair Visor Support - Installation INSTALLATION 1. Place support into position. 2. Install mounting fasteners attaching support to roof header, 3. Engage sun visor to center support. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal > Page 8800 Sun Visor: Service and Repair Visor - Removal REMOVAL CAUTION: When removing or installing the screws (1), be certain to avoid any wiring or drain tube interference. 1. Remove the three screws (1) that secure each sun visor (2) to the roof panel and remove the visor from the headliner (3). 2. If equipped, disconnect the wire harness connector for the illuminated vanity mirror (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal > Page 8801 Sun Visor: Service and Repair Visor - Installation INSTALLATION CAUTION: When removing or installing the screws (1), be certain to avoid any wiring or drain tube interference. 1. If equipped, connect the wire harness connector for the illuminated vanity mirror (4). 2. Position the sun visor (2) onto the headliner (3). 3. Install the three screws (1) that secure each sun visor to the roof panel. Tighten the screws to 2.2 Nm (20 in. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal Trim Panel: Service and Repair Cowl Trim Panel - Removal REMOVAL 1. Remove door sill trim panel.See: Scuff Plate/Service and Repair/Scuff Plate - Removal. 2. Using trim stick C-4755, disengage cowl trim panel clips from the corresponding locations in the sheet metal. 3. Remove cowl trim panel from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8806 Trim Panel: Service and Repair Cowl Trim Panel - Installation INSTALLATION 1. Ensure plastic retaining nut (3) is installed. 2. Position cowl trim panel (1) to vehicle. 3. Hand press cowl trim panel to corresponding holes in sheet metal. 4. Install door sill trim panel.See: Scuff Plate/Service and Repair/Scuff Plate - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8807 Trim Panel: Service and Repair Luggage Compartment Trim Quarter Trim Panel - Removal REMOVAL 1. Remove the second row seats. See: Seats/Service and Repair/Seats, Front/Seat - Removal. 2. Remove the third row seats, if equipped. See: Seats/Service and Repair/Seats, Front/Seat Removal 3. Remove the storage box, if equipped. See: Utility Storage Compartment/Service and Repair/Rear Storage Box - Removal. 4. Remove the door sill plate. See: Scuff Plate/Service and Repair/Scuff Plate - Removal. 5. Remove the D-pillar trim panel. See: Pillar Trim/D-Pillar Trim/Removal. 6. Remove the mounting fasteners. 7. Using trim stick C-4755, carefully pry the quarter trim panel out disengaging the retaining clips. Quarter Trim Panel - Installation INSTALLATION 1. Install the quarter trim panel. 2. Install the mounting fasteners. 3. Install the door sill plate. See: Scuff Plate/Service and Repair/Scuff Plate - Installation. 4. Install the D-pillar trim panel. See: Pillar Trim/D-Pillar Trim/Installation. 5. Install the storage box, if equipped. See: Utility Storage Compartment/Service and Repair/Rear Storage Box - Installation. 6. Install the third row seats, if equipped. See: Seats/Service and Repair/Seats, Front/Seat - Installation. 7. Install the second row seats. See: Seats/Service and Repair/Seats, Front/Seat - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8808 Trim Panel: Service and Repair Pillar Trim A-Pillar Trim Panel-Removal REMOVAL CAUTION: If the high-retention snap clip (3) is removed from the sheet metal, it will be damaged and must be replaced with a new tether and snap clip unit. Also, if the rosebud on the plastic tether is damaged due to misalignment and does not engage, it must be replaced with a new plastic tether. 1. Carefully pull the upper end of the trim away from the A-pillar far enough to disengage the rosebud retainer (6) and unfold the tether (2). 2. Using a screwdriver or equivalent, carefully disengage the tether clip (1) and slide from housing on the A-pillar trim panel. 3. Carefully pull the bottom end of the trim away from the A-pillar to disengage the spring clip retainer. 4. Remove A-pillar trim from vehicle. A-Pillar Trim Panel-Installation INSTALLATION CAUTION: If the high-retention snap clip (3) is removed from the sheet metal, it will be damaged and must be replaced with a new tether and snap clip unit. Also, if the rosebud on the plastic tether is damaged due to misalignment and does not engage, it must be replaced with a new plastic tether. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8809 1. Place A-pillar trim (1) into position. 2. Carefully push the bottom end of the trim onto the A-pillar to engage the spring clip retainer. 3. Carefully slide the tether (2) into the housing on the A-pillar trim panel and engage the tether clip (1). 4. Carefully engage the rosebud retainer (6) and push the upper end of the trim to the A-pillar and engage the spring clip retainer. B-Pillar Trim Panel-Installation INSTALLATION 1. Insert top of B-pillar trim locator into position. 2. Before hinging B-pillar upward into place, route seat belt anchor through seat belt adjuster opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8810 3. Fasten seat belt anchor to seat.See: Restraint Systems/Seat Belt Systems/Seat Belt Height Adjuster/Service and Repair/Seat Belt Turning Loop Adjuster - Installation 4. Hinge B-pillar trim downward, engaging clips ensuring proper seat. 5. Install B-pillar screw into B-pillar. 6. Snap SRS airbag anchor cover into place ensuring proper seat. 7. Install the lower B-pillar trim panel. 8. Install the sill trim panel. See: Scuff Plate/Service and Repair/Scuff Plate - Installation. B-Pillar Trim Panel-Removal REMOVAL 1. Remove sill trim panel.See: Scuff Plate/Service and Repair/Scuff Plate - Removal 2. Remove seat belt anchor.See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal 3. Remove the lower B-pillar trim panel. 4. Using trim stick C-4755, remove SRS airbag cover located at top of B-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8811 5. Move seat belt adjuster all the way down exposing the B-pillar screw. Remove B-pillar screw. 6. Using trim stick C-4755, pry up B-pillar and route seat belt through B-pillar trim. Remove B-pillar bottom first and remove trim from B-pillar. C-Pillar Trim Panel-Removal REMOVAL 1. Remove the quarter trim panel. See: Luggage Compartment Trim/Quarter Trim Panel - Removal. 2. Remove seat belt anchor bolt, See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal. 3. Remove the access hole cover and remove the mounting fastener. 4. Using trim stick C-4755, carefully pry the C-pillar out disengaging the retaining clips. 5. Route seat belt through opening and remove C-pillar trim panel from vehicle. C-Pillar Trim Panel-Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8812 1. Place upper C-pillar trim into position. 2. Route seat belt through opening in C-Pillar Trim 3. Firmly seat the retaining clips to the C-pillar. 4. Install the mounting fastener and access hole cover. 5. Install bolt attaching seat belt lower anchor to floor, See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Installation. 6. Install quarter panel trim. See: Luggage Compartment Trim/Quarter Trim Panel - Installation. Removal REMOVAL 1. Remove the rear header trim panel. 2. Remove the access hole covers and remove the mounting fasteners. 3. Using trim stick C-4755, carefully pry the D-pillar out disengaging the retaining clips. 4. Remove the D-pillar from the vehicle. Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8813 1. Position the D-pillar into position. 2. Firmly seat the retaining clips securing the D-pillar. 3. Install mounting fasteners and access hole covers. 4. Install the rear header trim panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8814 Trim Panel: Service and Repair Cowl Trim Panel - Removal REMOVAL 1. Remove door sill trim panel.See: Scuff Plate/Service and Repair/Scuff Plate - Removal. 2. Using trim stick C-4755, disengage cowl trim panel clips from the corresponding locations in the sheet metal. 3. Remove cowl trim panel from vehicle. Cowl Trim Panel - Installation INSTALLATION 1. Ensure plastic retaining nut (3) is installed. 2. Position cowl trim panel (1) to vehicle. 3. Hand press cowl trim panel to corresponding holes in sheet metal. 4. Install door sill trim panel.See: Scuff Plate/Service and Repair/Scuff Plate - Installation. Quarter Trim Panel - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8815 1. Remove the second row seats. See: Seats/Service and Repair/Seats, Front/Seat - Removal. 2. Remove the third row seats, if equipped. See: Seats/Service and Repair/Seats, Front/Seat Removal 3. Remove the storage box, if equipped. See: Utility Storage Compartment/Service and Repair/Rear Storage Box - Removal. 4. Remove the door sill plate. See: Scuff Plate/Service and Repair/Scuff Plate - Removal. 5. Remove the D-pillar trim panel. See: Pillar Trim/D-Pillar Trim/Removal. 6. Remove the mounting fasteners. 7. Using trim stick C-4755, carefully pry the quarter trim panel out disengaging the retaining clips. Quarter Trim Panel - Installation INSTALLATION 1. Install the quarter trim panel. 2. Install the mounting fasteners. 3. Install the door sill plate. See: Scuff Plate/Service and Repair/Scuff Plate - Installation. 4. Install the D-pillar trim panel. See: Pillar Trim/D-Pillar Trim/Installation. 5. Install the storage box, if equipped. See: Utility Storage Compartment/Service and Repair/Rear Storage Box - Installation. 6. Install the third row seats, if equipped. See: Seats/Service and Repair/Seats, Front/Seat - Installation. 7. Install the second row seats. See: Seats/Service and Repair/Seats, Front/Seat - Installation. A-Pillar Trim Panel-Removal REMOVAL CAUTION: If the high-retention snap clip (3) is removed from the sheet metal, it will be damaged and must be replaced with a new tether and snap clip unit. Also, if the rosebud on the plastic tether is damaged due to misalignment and does not engage, it must be replaced with a new plastic tether. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8816 1. Carefully pull the upper end of the trim away from the A-pillar far enough to disengage the rosebud retainer (6) and unfold the tether (2). 2. Using a screwdriver or equivalent, carefully disengage the tether clip (1) and slide from housing on the A-pillar trim panel. 3. Carefully pull the bottom end of the trim away from the A-pillar to disengage the spring clip retainer. 4. Remove A-pillar trim from vehicle. A-Pillar Trim Panel-Installation INSTALLATION CAUTION: If the high-retention snap clip (3) is removed from the sheet metal, it will be damaged and must be replaced with a new tether and snap clip unit. Also, if the rosebud on the plastic tether is damaged due to misalignment and does not engage, it must be replaced with a new plastic tether. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8817 1. Place A-pillar trim (1) into position. 2. Carefully push the bottom end of the trim onto the A-pillar to engage the spring clip retainer. 3. Carefully slide the tether (2) into the housing on the A-pillar trim panel and engage the tether clip (1). 4. Carefully engage the rosebud retainer (6) and push the upper end of the trim to the A-pillar and engage the spring clip retainer. B-Pillar Trim Panel-Installation INSTALLATION 1. Insert top of B-pillar trim locator into position. 2. Before hinging B-pillar upward into place, route seat belt anchor through seat belt adjuster opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8818 3. Fasten seat belt anchor to seat.See: Restraint Systems/Seat Belt Systems/Seat Belt Height Adjuster/Service and Repair/Seat Belt Turning Loop Adjuster - Installation 4. Hinge B-pillar trim downward, engaging clips ensuring proper seat. 5. Install B-pillar screw into B-pillar. 6. Snap SRS airbag anchor cover into place ensuring proper seat. 7. Install the lower B-pillar trim panel. 8. Install the sill trim panel. See: Scuff Plate/Service and Repair/Scuff Plate - Installation. B-Pillar Trim Panel-Removal REMOVAL 1. Remove sill trim panel.See: Scuff Plate/Service and Repair/Scuff Plate - Removal 2. Remove seat belt anchor.See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal 3. Remove the lower B-pillar trim panel. 4. Using trim stick C-4755, remove SRS airbag cover located at top of B-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8819 5. Move seat belt adjuster all the way down exposing the B-pillar screw. Remove B-pillar screw. 6. Using trim stick C-4755, pry up B-pillar and route seat belt through B-pillar trim. Remove B-pillar bottom first and remove trim from B-pillar. C-Pillar Trim Panel-Removal REMOVAL 1. Remove the quarter trim panel. See: Luggage Compartment Trim/Quarter Trim Panel - Removal. 2. Remove seat belt anchor bolt, See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal. 3. Remove the access hole cover and remove the mounting fastener. 4. Using trim stick C-4755, carefully pry the C-pillar out disengaging the retaining clips. 5. Route seat belt through opening and remove C-pillar trim panel from vehicle. C-Pillar Trim Panel-Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8820 1. Place upper C-pillar trim into position. 2. Route seat belt through opening in C-Pillar Trim 3. Firmly seat the retaining clips to the C-pillar. 4. Install the mounting fastener and access hole cover. 5. Install bolt attaching seat belt lower anchor to floor, See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Installation. 6. Install quarter panel trim. See: Luggage Compartment Trim/Quarter Trim Panel - Installation. Removal REMOVAL 1. Remove the rear header trim panel. 2. Remove the access hole covers and remove the mounting fasteners. 3. Using trim stick C-4755, carefully pry the D-pillar out disengaging the retaining clips. 4. Remove the D-pillar from the vehicle. Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8821 1. Position the D-pillar into position. 2. Firmly seat the retaining clips securing the D-pillar. 3. Install mounting fasteners and access hole covers. 4. Install the rear header trim panel. Shifter Housing - Removal REMOVAL AUTOMATIC 1. Disengage the lower cover of the shift knob (1) to access set screw. 2. Remove set screw and remove shift knob. 3. Carefully pry up the shift bezel (2) and remove. MANUAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8822 1. Disengage the lower cover of the shift knob (4) to access set screw. 2. Remove set screw and remove shift knob. 3. Carefully pry up the shift bezel (3) and remove. 4. Carefully pry up on the shift boot (1) and remove from shift shaft (2). Shifter Housing - Installation INSTALLATION AUTOMATIC 1. Install the shift bezel (2). 2. Remove set screw and remove shift knob (1). 3. Install the lower cover. MANUAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Panel - Removal > Page 8823 1. Install the shift boot (1). 2. Install the shift bezel (3). 3. Install the shift knob (4) and install the set screw. 4. Install the lower cover. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal Utility Storage Compartment: Service and Repair Second Row Storage Bin - Removal REMOVAL 1. Open the lid to the second row storage bin and remove the inner liner. 2. Remove the mounting fasteners securing the storage bin to the floor. 3. Remove the storage bin from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8828 Utility Storage Compartment: Service and Repair Second Row Storage Bin - Installation INSTALLATION 1. Place the storage bin into position in the vehicle. 2. Install the mounting fasteners that secure the storage bin to the floor. 3. Install the liner and close the lid. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8829 Utility Storage Compartment: Service and Repair Rear Storage Bin - Removal REMOVAL 1. Remove the carpet (1) covering the storage bin. 2. Remove the storage bin liner (3). 3. Remove the mounting fasteners (4). 4. Remove the storage bin (5) from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8830 Utility Storage Compartment: Service and Repair Rear Storage Bin - Installation INSTALLATION 1. Install the storage bin (5) to the vehicle. 2. Install the mounting fasteners (4). 3. Install the storage bin liner (3). 4. Install the carpet (1) covering the storage bin. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8831 Utility Storage Compartment: Service and Repair Second Row Storage Bin - Removal REMOVAL 1. Open the lid to the second row storage bin and remove the inner liner. 2. Remove the mounting fasteners securing the storage bin to the floor. 3. Remove the storage bin from the vehicle. Second Row Storage Bin - Installation INSTALLATION 1. Place the storage bin into position in the vehicle. 2. Install the mounting fasteners that secure the storage bin to the floor. 3. Install the liner and close the lid. Rear Storage Bin - Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8832 1. Remove the carpet (1) covering the storage bin. 2. Remove the storage bin liner (3). 3. Remove the mounting fasteners (4). 4. Remove the storage bin (5) from the vehicle. Rear Storage Bin - Installation INSTALLATION 1. Install the storage bin (5) to the vehicle. 2. Install the mounting fasteners (4). 3. Install the storage bin liner (3). 4. Install the carpet (1) covering the storage bin. Rear Storage Box - Removal REMOVAL STORAGE BOX - 5 PASSENGER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8833 1. Remove the mat covering the storage box. 2. Remove the load floor assembly (3). 3. Remove the storage box mounting fasteners (2). 4. Remove the storage box (1) from the vehicle. STORAGE BOX - 7 PASSENGER 1. Remove the retainers on the seat back gap hider to the rear storage box. 2. Open the storage bin lid. 3. Remove the storage box liner (2), if equipped. 4. Remove the storage box mounting fasteners (4). 5. Remove the storage box (1) from the vehicle. Rear Storage Box - Installation INSTALLATION STORAGE BOX - 5 PASSENGER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Second Row Storage Bin - Removal > Page 8834 1. Install the storage box (1) to the vehicle. 2. Install the storage box mounting fasteners (2). 3. Install the load floor assembly (3). 4. Install the mat covering the storage box. STORAGE BOX - 7 PASSENGER 1. Install the storage box (1) to the vehicle. 2. Install the storage box mounting fasteners (4). 3. Install the storage box liner (2). 4. Install the seat back gap hider retainers to the rear storage box. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal > Page 8841 Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Installation INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Install door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Driver Door Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Driver Door Module > Page 8846 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way Door Module: Diagrams Driver Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8849 Door Module: Diagrams Driver Door Module C3 (Express) (Front Door) 5 Way Connector C3 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8850 Door Module: Diagrams Driver Door Module C4 (Express) (Front Door) 5 Way Connector C4 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8851 Door Module: Diagrams Driver Door Module C5 (Express) (Front Door) 10 Way Connector C5 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8852 Door Module: Diagrams Driver Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Driver Door Module C3 (Express) (Front Door) 5 Way Connector C3 (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8853 MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Driver Door Module C4 (Express) (Front Door) 5 Way Connector C4 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8854 Driver Door Module C5 (Express) (Front Door) 10 Way Connector C5 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Passenger Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8855 MODULE-DOOR-PASSENGER (EXPRESS) - (FRONT DOOR) 10 WAY Passenger Door Module C3 (Except Base) (Front Door) 5 Way Connector C3 (EXCEPT BASE) - (FRONT DOOR) 5 WAY MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8856 Passenger Door Module C4 (Except Base) (Front Door) 5 Way Connector C4 (EXCEPT BASE) - (FRONT DOOR) 5 WAY MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 5 WAY Passenger Door Module C5 (Except Base) (Front Door) 10 Way Connector C5 (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8857 MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Service and Repair > Door Module - Removal Door Module: Service and Repair Door Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel as necessary to gain access to the door control module. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the electrical connectors. 4. Remove the door control module mounting fasteners and remove the module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Service and Repair > Door Module - Removal > Page 8860 Door Module: Service and Repair Door Module - Installation INSTALLATION 1. Place the door control module into position and install the mounting fasteners. 2. Connect the electrical connectors. 3. Install the door trim panel. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Installation. 4. Install the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8865 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8866 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description Keyless Start Antenna: Description and Operation Remote Start Antenna - Description DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the Wireless Ignition Node (WIN) (1), a length of coaxial cable (2), two mounting clips (3 and 4) and a control module/antenna (5). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation > Remote Start Antenna - Description > Page 8872 Keyless Start Antenna: Description and Operation Remote Start Antenna - Operation OPERATION The remote start antenna is an external hidden antenna located at the driver's side front of dash. The antenna interfaces with the Wireless Integration Node (WIN) through a coaxial electrical cable and electrical connector. The antenna helps to amplify the signal for the Remote Keyless Entry (RKE) key fob. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components. Failure to do this may result in serious or fatal injury. The remote start antenna is located driver's side front of dash. 1. Disconnect and isolate the battery negative cable. 2. Remove radio. Refer to See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 3. Remove instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. 4. Remove the instrument panel top pad. Refer to See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. NOTE: During removal of the remote start antenna note the routing location of the coaxial cable. 5. Disconnect remote start antenna coaxial cable connector (1) from skreem module (3). 6. Remove the mounting clip (2). 7. Remove the mounting clip at the steering column reinforcement bracket. 8. Remove screws (1) and remove remote start antenna (2) from instrument panel assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 8875 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION NOTE: Make sure the remote start antenna is positioned the same way noted during the removal procedure. 1. Install the remote start antenna (2) and screws (1) to instrument panel assembly. Tighten to 2.5 Nm (22 in. lbs.). 2. Route the remote start coaxial cable in the position noted during the removal procedure. 3. Install the coaxial cable mounting clip at the steering column reinforcement bracket. 4. Install the mounting clip (2). 5. Connect remote start antenna coaxial cable connector (1) to skreem module (3). 6. Install instrument cluster. Refer to See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Installation. 7. Install radio. Refer to See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 8. Install the instrument panel top pad. Refer to See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. 9. Connect negative battery cable. Tighten to 5 Nm (45 in. lbs.) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair FOBIK TRANSMITTER BATTERY REPLACEMENT FOBIK WITH BATTERY COVER NOTE: Do not disturb the metal terminal near the battery. Avoid touching the new battery. Skin oils may cause battery deterioration. If battery are touched, clean with rubbing alcohol. To replace the FOBIK transmitter battery: 1. Using a small flat bladed tool, carefully remove the battery cover on the back of the FOBIK. 2. Remove the battery one at a time by slightly lifting up and sliding out from the FOBIK. 3. Replace the battery with the same type of battery cell. 4. Install the battery with the positive terminal up. 5. Install battery cover and snap into place. 6. Test FOBIK operation. FOBIK WITHOUT BATTERY COVER Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 8880 NOTE: Do not disturb the metal terminal near the battery. Avoid touching the new battery. Skin oils may cause battery deterioration. If battery are touched, clean with rubbing alcohol. This design is a clam shell design whereby both halves are split apart. 1. Remove the valet/spare key from the FOBIK if present. 2. Using a trim stick C-4755 or equivalent, carefully separate the top half from the bottom half. 3. Lift up on the battery to remove. 4. Replace battery with the same type of cell. 5. Install new battery negative side up. 6. Snap the top and bottom halves together. 7. Test FOBIK operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal > Page 8886 Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Installation INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Install door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver Door Latch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver Door Latch > Page 8891 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver Door Latch > Page 8892 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Driver Door Latch > Page 8893 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way Power Door Lock Actuator: Diagrams Driver Door Latch (Except Thatcham) (Front Door) 4 Way Connector (EXCEPT THATCHAM) - (FRONT DOOR) 4 WAY LATCH-DOOR-DRIVER (EXCEPT THATCHAM) - (FRONT DOOR) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8896 Power Door Lock Actuator: Diagrams Driver Door Latch (Thatcham) (Front Door) 8 Way Connector (THATCHAM) - (FRONT DOOR) 8 WAY LATCH-DOOR-DRIVER (THATCHAM) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8897 Power Door Lock Actuator: Diagrams Left Rear Door Latch (Except Thatcham) (Rear Door) 4 Way Connector (EXCEPT THATCHAM) - (REAR DOOR) 4 WAY LATCH-DOOR-LEFT REAR (EXCEPT THATCHAM) - (REAR DOOR) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8898 Power Door Lock Actuator: Diagrams Left Rear Door Latch (Thatcham) (Rear Door) 8 Way Connector (THATCHAM) - (REAR DOOR) 8 WAY LATCH-DOOR-LEFT REAR (THATCHAM) - (REAR DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8899 Power Door Lock Actuator: Diagrams Driver Door Latch (Except Thatcham) (Front Door) 4 Way Connector (EXCEPT THATCHAM) - (FRONT DOOR) 4 WAY LATCH-DOOR-DRIVER (EXCEPT THATCHAM) - (FRONT DOOR) 4 WAY Driver Door Latch (Thatcham) (Front Door) 8 Way Connector (THATCHAM) - (FRONT DOOR) 8 WAY LATCH-DOOR-DRIVER (THATCHAM) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8900 Left Rear Door Latch (Except Thatcham) (Rear Door) 4 Way Connector (EXCEPT THATCHAM) - (REAR DOOR) 4 WAY LATCH-DOOR-LEFT REAR (EXCEPT THATCHAM) - (REAR DOOR) 4 WAY Left Rear Door Latch (Thatcham) (Rear Door) 8 Way Connector (THATCHAM) - (REAR DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8901 LATCH-DOOR-LEFT REAR (THATCHAM) - (REAR DOOR) 8 WAY Passenger Door Latch (Except Thatcham) (Front Door) 4 Way Connector (EXCEPT THATCHAM) - (FRONT DOOR) 4 WAY LATCH-DOOR-PASSENGER (EXCEPT THATCHAM) - (FRONT DOOR) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8902 Passenger Door Latch (Thatcham) (Front Door) 8 Way Connector (THATCHAM) - (FRONT DOOR) 8 WAY LATCH-DOOR-PASSENGER (THATCHAM) - (FRONT DOOR) 8 WAY Right Rear Door Latch (Except Thatcham) (Rear Door) 4 Way Connector (EXCEPT THATCHAM) - (REAR DOOR) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8903 LATCH-DOOR-RIGHT REAR (EXCEPT THATCHAM) - (REAR DOOR) 4 WAY Right Rear Door Latch (Thatcham) (Rear Door) 8 Way Connector (THATCHAM) - (REAR DOOR) 8 WAY LATCH-DOOR-RIGHT REAR (THATCHAM) - (REAR DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (Except Thatcham) (Front Door) 4 Way > Page 8904 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 8905 Power Door Lock Actuator: Testing and Inspection DOOR LOCK MOTOR Make certain battery is in normal condition before circuits are tested. To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem maybe caused by a shorted motor, a bad switch, or a bad relay. Disconnecting a defective motor will allow the others to work. To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 volt power source to the positive pin of the lock motor and a ground wire to the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the motor. The door lock motor is integral to the door latch. If faulty, the entire door latch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch > Page 8910 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 8913 Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C2 (Front Door) 10 Way Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 8914 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Except Base) (Front Door) 10 Way Connector (EXCEPT BASE) - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 8915 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Base) (Front Door) 8 Way Connector (BASE) - (FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (BASE) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 8916 Power Door Lock Switch: Testing and Inspection DIAGNOSIS AND TESTING VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: - Touch other test light lead to battery feed B+ terminal. - If test light comes on, the wiring circuit between the battery and switch is functional. - If test light does not come on, check for a blown fuse. Refer to Wiring Diagrams for circuit information. DOOR LOCK SWITCH NOTE: Vehicles equipped with the auto-express feature for power windows, the local interface network (LIN) controls the lock, mirror and window features. Remove the non-express switch from its mounting location. Using an ohmmeter, refer to the DOOR LOCK SWITCH CONTINUITY table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. DOOR LOCK SWITCH CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 8919 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Connect switch wire connector. 2. Install the switch by snapping into place. 3. Connect the battery negative remote cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 8925 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Connect switch wire connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID PAINT CODES Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description DESCRIPTION On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 8932 Paint: Description and Operation Paint Code - Description DESCRIPTION The paint code is identified on the Vehicle Safety Certification Label which is located on the drivers door shut face. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The codes listed in the Color Code Chart are used for manufacturing purposes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar(R) Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. For a description of the paint codes, See: Application and ID. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Personal injury can result. TOUCH UP PROCEDURE 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar(R) Tar/Road Oil Remover, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in 4. Allow clear top coat to dry hard. If desired, 5 can be performed on clear top coat. WARNING: Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 8935 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Driver Door Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Driver Door Module > Page 8941 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way Door Module: Diagrams Driver Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8944 Door Module: Diagrams Driver Door Module C3 (Express) (Front Door) 5 Way Connector C3 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8945 Door Module: Diagrams Driver Door Module C4 (Express) (Front Door) 5 Way Connector C4 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8946 Door Module: Diagrams Driver Door Module C5 (Express) (Front Door) 10 Way Connector C5 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8947 Door Module: Diagrams Driver Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Driver Door Module C3 (Express) (Front Door) 5 Way Connector C3 (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8948 MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Driver Door Module C4 (Express) (Front Door) 5 Way Connector C4 (EXPRESS) - (FRONT DOOR) 5 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8949 Driver Door Module C5 (Express) (Front Door) 10 Way Connector C5 (EXPRESS) - (FRONT DOOR) 10 WAY MODULE-DOOR-DRIVER (EXPRESS) - (FRONT DOOR) 10 WAY Passenger Door Module C2 (Express) (Front Door) 10 Way Connector C2 (EXPRESS) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8950 MODULE-DOOR-PASSENGER (EXPRESS) - (FRONT DOOR) 10 WAY Passenger Door Module C3 (Except Base) (Front Door) 5 Way Connector C3 (EXCEPT BASE) - (FRONT DOOR) 5 WAY MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8951 Passenger Door Module C4 (Except Base) (Front Door) 5 Way Connector C4 (EXCEPT BASE) - (FRONT DOOR) 5 WAY MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 5 WAY Passenger Door Module C5 (Except Base) (Front Door) 10 Way Connector C5 (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C2 (Express) (Front Door) 10 Way > Page 8952 MODULE-DOOR-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Door Module - Removal Door Module: Service and Repair Door Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel as necessary to gain access to the door control module. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the electrical connectors. 4. Remove the door control module mounting fasteners and remove the module from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Door Module - Removal > Page 8955 Door Module: Service and Repair Door Module - Installation INSTALLATION 1. Place the door control module into position and install the mounting fasteners. 2. Connect the electrical connectors. 3. Install the door trim panel. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Installation. 4. Install the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 8959 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 8960 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 12 WAY NODE-WIRELESS IGNITION - (INSTRUMENT PANEL) 12 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 8964 Seat Heater Control Module: Diagrams Connector - (SEAT) 10 WAY MODULE-HEATED SEATS - (SEAT) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located under the driver front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan (4). The module can be accessed from under the Driver seat with the seat in the full back and up position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 8967 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate Diagnostic Trouble Code (DTC). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 8968 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the driver front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 8971 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8976 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8977 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Left Trailer Tow Stop Lamp Relay > Page 8978 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Trailer Towing Relay: Diagrams Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8981 Trailer Towing Relay: Diagrams Right Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP LAMP-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8982 Trailer Towing Relay: Diagrams Left Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-LEFT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Left Trailer Tow Stop Lamp Relay (Except Export) (Trailer Tow) 5 Way > Page 8983 Trailer Towing Relay: Diagrams Right Trailer Tow Stop/Turn Relay (Except Export) (Trailer Tow) 5 Way Connector (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW STOP/TURN-RIGHT (EXCEPT EXPORT) - (TRAILER TOW) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional trailer tow preparation package have four trailer tow relays, one each for the trailer tow stop/turn right and left and one each for the trailer stop lamp right and left. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are included with the trailer tow preparation wire harness that is shipped loose in the glove box for customer or dealer installation at the rear of the vehicle. A trailer tow stop/turn relay is located behind the rear fascia below each outer tail lamp, while a trailer stop lamp relay is located behind the rear fascia below each outboard end of the rear bumper reinforcement. Each relay and connector is wrapped within an isolator envelope for sound deadening and anti-rattle protection. Refer to the appropriate wiring information for specific relay cavity assignment information. Any of the trailer tow relays cannot be adjusted or repaired and, if ineffective or damaged, the affected unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 8986 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Totally Integrated Power Module (TIPM) to the tail lamps to control a high current output to the trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right trailer tow stop/turn signal pins of the 4-way trailer tow connector at all times. The common feed terminals of both the left and right trailer tow stop relays is connected to the normally closed (87A) terminal of their respective left or right trailer tow stop/turn relay at all times. - Coil Ground Terminal (85) - The coil ground terminal of both the left and right trailer tow stop/turn relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. The coil ground terminals of both the left and right trailer tow stop relays are connected to the stop lamp control circuit from the TIPM at all times. - Coil Battery Terminal (86) - The coil battery terminal of both the left and right trailer tow stop/turn relays is connected to a path to ground at all times. The coil battery terminal of both the left and right trailer tow stop relays is connected to their respective left or right rear turn signal control circuits from the TIPM at all times. - Normally Open Terminal (87) - The normally open terminal of both the left and right trailer tow stop/turn relays is connected to the stop lamp control circuit from the TIPM whenever that relay is energized. The normally open terminal of both the left and right trailer tow stop relays is connected to a path to ground whenever that relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal of both the left and right trailer tow stop/turn relays is connected are connected to the common supply (30) terminal of their respective left or right trailer tow stop relay whenever the relay is de-energized. The normally closed terminal of both the left and right trailer tow stop relays is not connected to any circuit in this application. The trailer tow relays and the hard wired circuits for the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that provide some features of the trailer tow turn and stop lamp lighting system. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to trailer tow turn and stop lamp lighting operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal Trailer Towing Relay: Service and Repair Trailer Tow Relay - Removal REMOVAL TRAILER TOW STOP/TURN RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Removal 3. Disengage the left or right trailer tow stop/turn relay and connector from the isolator envelope (3) secured to the trailer tow wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Pull the relay straight out from the wire harness connector. TRAILER TOW STOP LAMP RELAYS 1. Disconnect and isolate the battery negative cable. 2. Remove the rear fascia from the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Removal 3. Disengage the left or right trailer tow stop lamp relay and connector from the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Pull the relay straight out from the wire harness connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Service and Repair > Trailer Tow Relay - Removal > Page 8989 Trailer Towing Relay: Service and Repair Trailer Tow Relay - Installation INSTALLATION TRAILER TOW STOP/TURN RELAYS 1. Align the terminals of the left or right trailer tow stop/turn relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (3) secured to the wire harness (6) along the left or right body side aperture (2) just below the outer tail lamp. 4. Reinstall the rear fascia onto the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Installation. 5. Reconnect the battery negative cable. TRAILER TOW STOP LAMP RELAYS 1. Align the terminals of the left or right trailer tow stop lamp relay with the terminal receptacles of the trailer tow wire harness connector. 2. Firmly and evenly push the relay into the connector until it is fully seated. 3. Insert the relay and connector into the isolator envelope (4) secured to the trailer tow wire harness (6) on the underside of the rear bumper reinforcement (1) on the left or right side of the 4-way trailer tow connector (5). 4. Reinstall the rear fascia onto the vehicle. See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Rack - Removal Luggage Rack: Service and Repair Luggage Rack - Removal REMOVAL 1. Remove the luggage rack crossbars. 2. Remove the front and rear covers of the luggage rack rails. 3. Remove the mounting fasteners. 4. Carefully remove the luggage rack rails from the top of the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Rack - Removal > Page 8995 Luggage Rack: Service and Repair Luggage Rack - Installation INSTALLATION 1. Carefully install the luggage rack rails to the top of the vehicle. 2. Install the mounting fasteners. 3. Install the front and rear covers of the luggage rack rails. 4. Install the luggage rack crossbars. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade - Removal Sun Shade: Service and Repair Sunroof Sunshade - Removal REMOVAL 1. Remove the drain trough, See: Sunroof / Moonroof Track/Service and Repair/Sunroof Trough Removal 2. Push up the front center of the sunshade (1) to pop out the front two feet. 3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade - Removal > Page 9001 Sun Shade: Service and Repair Sunroof Sunshade - Installation INSTALLATION 1. Verify the sunshade track is free of obstructions like the trim lace/ring. 2. Start with sunshade (2) at an angle with one foot (1) in the track. 3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as the first foot. 4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into the track. 5. Check that all the feet are in the right track and verify sunshade operation. 6. Install the drain trough, See: Sunroof / Moonroof Track/Service and Repair/Sunroof Trough Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9005 Sunroof / Moonroof Motor: Diagrams Connector - (HEADLINER) 10 WAY MOTOR-SUNROOF - (HEADLINER) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Drive Motor Teach Procedure Sunroof / Moonroof Motor: Testing and Inspection Drive Motor Teach Procedure DRIVE MOTOR TEACH PROCEDURE REPLACEMENT DRIVE MOTOR 1. Upon first powering up the sunroof, continuously press the close button on the power sunroof switch. The sunroof will begin moving in the tilt up direction. 2. The glass panel will move to the hard stop (just past the full tilt position) and then reverse to the soft stop (the full tilt position). 3. Once the sunroof has reversed immediately (within 5 seconds of stopping travel), release the switch and continuously press the close button again. 4. The sunroof glass will continue to move to the fully closed position. Once fully closed the close button can be released. ORIGINAL DRIVE MOTOR 1. Cycle the sunroof to full close position and release close button on the power sunroof switch. 2. Once the sunroof is in the fully closed position, press and continuously hold the close button again. 3. After a ten second delay the sunroof will begin to move past the normal vent position to the hard stop position. It will then reverse to the normal full vent position (also called the soft stop). 4. Once the sunroof has reversed to the vent soft stop, immediately (within 5 seconds of stopping travel) release the close button and continuously press it again. 5. After a three second delay the sunroof glass will continue to move to the fully closed position. Once fully closed the close button can be released. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Drive Motor Teach Procedure > Page 9008 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor With Control Unit DRIVE MOTOR TEACH PROCEDURE REPLACEMENT DRIVE MOTOR 1. Press and hold the sunroof switch open until the sunroof glass fully opens, automatically reverses direction, and stops at a position just forward of the full open position. 2. Release sunroof switch. 3. Within five seconds of releasing sunroof switch, press and hold the sunroof switch open again until the sunroof glass closes, goes into vent position, and then finally stops in the closed position. 4. Release sunroof switch. Sunroof will now operate normally. ORIGINAL DRIVE MOTOR 1. Press and hold sunroof switch open until the sunroof glass opens and stops. 2. Release sunroof switch. 3. Press and hold sunroof switch open once again for at least 10 seconds. After 10 seconds of pressing the switch open, the sunroof glass will automatically move and stop at a new location. 4. Release sunroof switch. 5. Within five seconds of releasing the sunroof switch, press and hold the switch open again until the sunroof glass closes, goes into vent position, and then finally stops in the closed position. 6. Release sunroof switch. The sunroof will now operate normally. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor - Removal Sunroof / Moonroof Motor: Service and Repair Sunroof Motor - Removal REMOVAL 1. Remove headliner. See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner Removal 2. Disconnect the electrical connector (1). 3. Remove three motor assembly attaching screws (4) from bottom side of motor assembly (3) and remove motor assembly from the motor bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor - Removal > Page 9011 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor - Installation INSTALLATION 1. If sunroof was open when drive motor was removed, carefully move glass panel into closed position and remove glass panel. See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal 2. Set lifter arm timing by manually sliding the mechanisms (1) in the track until timing holes in the trollies are aligned with the timing holes in the lifter arm cams (2) and insert pins (3) into the mechanisms to hold mechanisms in closed position. 3. Place motor (3) into position and install screws (4) attaching motor to bracket (2). 4. Tighten the screws (4) to 3 Nm (26 in. lbs.). 5. If sunroof glass panel was removed previously, remove the timing pins and install the sunroof glass panel. See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Installation 6. Partially install the headliner and connect the sunroof wiring electrical connectors. See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation 7. Temporarily install sunroof switch and perform the sunroof motor teach procedure. See: Testing and Inspection/Drive Motor Teach Procedure. 8. Test sunroof operation, adjust glass as necessary. See: Sunroof / Moonroof Panel/Adjustments 9. Complete the headliner installation. See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 9015 Sunroof / Moonroof Switch: Diagrams Connector - (HEADLINER) 4 WAY SWITCH-SUNROOF - (HEADLINER) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced, See: Service and Repair/Sunroof Switch Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description > Page 9018 Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 9019 Sunroof / Moonroof Switch: Testing and Inspection SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the overhead console assembly, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. POWER SUNROOF SWITCH CONTINUITY TABLE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using a suitable flat bladed tool, release the mounting tabs from the sides of the sunroof control switch and pull the switch out of the overhead console assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal > Page 9022 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Installation INSTALLATION 1. Insert the sunroof control switch into the overhead console assembly. Push the switch until it is securely held in place by the mounting tabs. 2. Install the overhead console, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Trough - Removal Sunroof / Moonroof Track: Service and Repair Sunroof Trough - Removal REMOVAL 1. Remove the glass See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal. 2. Separate the trough pins (3) from the glass lift mechanisms (1). 3. Slide trough (1) to one side and push down on the center of the trough until the guide shoe tab (3) releases from the track (2). 4. Slide the trough in the opposite direction to release the other shoe and lift the trough out of the sunroof opening. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Trough - Removal > Page 9027 Sunroof / Moonroof Track: Service and Repair Sunroof Trough - Installation INSTALLATION 1. Insert one of the trough guides (3) and guide shoe (2) into the track. 2. Push down on the center of the trough (1) to flatten it out and install the remaining trough guide (3) and guide shoe (2) into the track. 3. Install the trough guide pins into the glass lift mechanism (3) and seat fully. 4. Install the glass See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal Sunroof / Moonroof Windguard: Service and Repair Wind Deflector - Removal REMOVAL 1. Open the sunroof glass to the full open position. 2. Press the spring lock (1) with a small flat bladed tool and push the wind deflector (2) reward to release from the car top opening. 3. Repeat the previous step on the opposite side. 4. Rotate the wind deflector (1) up and release from the mounting hole (2) in the sunroof frame. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal > Page 9032 Sunroof / Moonroof Windguard: Service and Repair Wind Deflector - Installation INSTALLATION 1. Position the wind deflector springs (1) into the mounting holes (2) in the sunroof frame. 2. Rotate forward and down into position. 3. Slide the wind deflector and spring (1) forward under the car top lip and make sure the spring lock snaps into place (2) fully. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Tube - Removal REMOVAL 1. Drop down the headliner as necessary to gain access to the drain hoses See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner Removal. 2. Disconnect the front hoses (2) from the sunroof assembly (1). 3. Release the support clips (3) and disconnect the lower grommet and remove the hose. 4. Disconnect the rear hoses (2) from the sunroof assembly (1) and release the support clips (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal > Page 9037 5. Separate the remaining support clips (1). 6. Disconnect the grommet (2) from the body (3) and remove the rear hoses as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal > Page 9038 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Tube - Installation INSTALLATION 1. Install the rear hoses (4) and connect the grommets (2) to the body (3). 2. Connect the support clips (1). 3. Route the hose as required and connect the remaining support clips (3). 4. Connect the hoses (2) to the sunroof assembly (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal > Page 9039 5. Connect the front hose lower grommet to the body. 6. Connect the front hose (2) to the sunroof assembly (1) and connect the support clips (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments GLASS PANEL 1. Move the sunshade rearward to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Adjust the glass one corner at a time. a. Loosen four glass screws (1). b. Lift glass assembly and align the top of the glass panel to the top of the roof panel. c. Tighten screw to 3 Nm (26 in. lbs.). d. Repeat steps a. and b. for each corner of the glass panel. e. When properly adjusted, the front of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface and the rear edge of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface. NOTE: When properly adjusted, the front of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 9043 NOTE: When properly adjusted, the rear edge of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface (2). 4. Verify sunroof operation and alignment. Check fit and re-adjust as necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass - Removal Sunroof / Moonroof Panel: Service and Repair Sunroof Glass - Removal REMOVAL 1. Slide sunshade rearward to the open position. 2. Move the glass panel to the closed position. 3. Remove the four glass panel screws (1). 4. Lift off glass panel and remove from vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass - Removal > Page 9046 Sunroof / Moonroof Panel: Service and Repair Sunroof Glass - Installation INSTALLATION 1. Position glass panel (2) on to mechanism lift arm. 2. Start the four attaching screws (1). 3. Center glass in opening by running a business card around the glass. 4. Adjust glass panel See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Removal REMOVAL 1. Remove sunroof glass panel See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Removal. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal > Page 9051 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Installation INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat - Removal Child Seat: Service and Repair Child Seat - Removal REMOVAL 1. Remove the appropriate seat cushion and place on a bench. See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Unzip the seat cover. 3. Partially remove the seat cushion cover to gain access to the booster seat fasteners. 4. Remove the booster seat mounting fasteners. 5. Unlatch the booster seat and carefully place in the upright position. 6. Disengage the booster seat cover trim clips. 7. Remove the booster seat from the seat cushion. 8. If required, disengage the seat cover clips and carefully pull the booster seat cover off the foam. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat - Removal > Page 9057 Child Seat: Service and Repair Child Seat - Installation INSTALLATION 1. If required, carefully pull the booster seat cover over the foam and engage the booster seat cover clips. 2. Install the booster seat to the seat cushion. 3. Engage the booster seat cover trim clips. 4. Latch the booster seat. 5. Install the booster seat mounting fasteners. Tighten to 13 N-m (10 ft. lbs.). 6. Install the seat cushion cover. 7. Zip the seat cover. 8. Install the seat cushion. See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Sleeve - Removal Head Rest: Service and Repair Headrest Sleeve - Removal REMOVAL NOTE: See: Description and Operation/Seats, Front for a detailed exploded view of the seats. 1. Remove the headrest. 2. If equipped, remove the back panel (14) or unzip the seat back cover. 3. Remove the J-clip from the bottom rear of the seat back. 4. Squeeze the detents at the bottom of the headrest guides then lightly tap the headrest guides (12) until the retaining clips disengage from the seat frame. 5. Remove the headrest guides from the seat back. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Sleeve - Removal > Page 9062 Head Rest: Service and Repair Headrest Sleeve - Installation INSTALLATION NOTE: See: Description and Operation/Seats, Front for a detailed exploded view of the seats. 1. Install the headrest guides to the seat back. 2. Lightly tap the headrest guides (12) until the retaining clips engage the seat frame. 3. Zip the seat back cover. 4. Install the J-clip to the bottom rear of the seat back. 5. Install the back panel (14), if equipped. 6. Install the headrest. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor > Page 9067 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor > Page 9068 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Seat) 4 Way Power Seat Motor: Diagrams Driver Seat Horizontal Adjuster Motor (Seat) 4 Way Connector - (SEAT) 4 WAY MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL - (SEAT) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Seat) 4 Way > Page 9071 Power Seat Motor: Diagrams Driver Seat Front Vertical Adjuster Motor (Seat) 4 Way Connector - (SEAT) 4 WAY MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL - (SEAT) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Seat) 4 Way > Page 9072 Power Seat Motor: Diagrams Driver Seat Rear Vertical Adjuster Motor (Seat) 4 Way Connector - (SEAT) 4 WAY MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL - (SEAT) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal Power Seat Motor: Service and Repair Power Seat Motor - Removal Fore Aft Motor REMOVAL WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the inoperative front seat assembly, See: Service and Repair/Seats, Front/Seat - Removal. 3. Remove the flex drive cable cover (2). a. Using a small flat bladed tool, release the mounting strap (1) that secures the flex drive cable cover (2) to the fore/aft motor (5). b. Pivot the cover away from the cable and pull it away from the seat frame (4) to disengage the cover slot from the mounting tab (3). 4. Remove the flex drive cable. a. Carefully bend the flex drive cable at the center and pull the motor end (3) away from the fore/aft motor (1) to disengage. b. Pull the cable out of the screw drive assembly (2) and remove from seat track. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9075 5. Disconnect the fore aft motor electrical connector. 6. Remove the fore/aft motor to mounting bracket retaining screws (1). 7. Remove the fore/aft motor (3). 8. Remove the short flex drive cable (2) from the seat frame assembly (4). Height Adjust Motor REMOVAL WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. 1. WARNING: Use caution when removing the height adjust motor and gearbox assembly (2) if the motor is inoperative, and the power seat is not in the full up position. The seat adjuster assembly is under load from the height adjust assist spring and may cause the motor to rotate under pressure when the fasteners are removed. The seat adjuster assembly also may spring upward when the motor is removed. If the height adjust motor is operative, move the power seat to the full up position prior to disconnecting the battery. Disconnect and isolate the battery negative cable. 2. Remove the inoperative front seat assembly, See: Service and Repair/Seats, Front/Seat Removal. 3. Disconnect the height adjust motor electrical connector. 4. Remove the height adjust motor gearbox spindle (1) retaining screw (4). 5. Remove the motor retaining screws (3). 6. Remove the height adjust motor and gearbox assembly (2) from the seat track. Tilt Motor REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9076 WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the inoperative front seat assembly, See: Service and Repair/Seats, Front/Seat - Removal. 3. Disconnect the front tilt motor electrical connector. 4. Remove the front tilt motor gearbox spindle (3) retaining screw (2). 5. Remove the motor retaining screws (4). 6. Remove the front tilt motor and gearbox assembly (1) from the seat track. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9077 Power Seat Motor: Service and Repair Power Seat Motor - Installation Fore Aft Motor INSTALLATION WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. CAUTION: Seat track side to side timing may be off if the fore aft motor was completely inoperative prior to removal. In the event the track timing is in question, proceed to 1 for track timing procedure. If track timing is not in question proceed to 2. 1. Using the square drive end of the old flex drive cable and a variable speed drill motor, drive the seat track screw drive assemblies reward until they reach the rear stops. a. Clamp one end of the old cable into the drill motor chuck. b. Put the other cable end into the seat track screw drive cable slot and slowly drive the seat track assembly reward until it reaches the rear stops. Take care not to bind the cable when the drive reaches the stop. c. Repeat this procedure for the other seat track. 2. Install the short flex drive cable (2) into the seat frame assembly (4). Ensure the square cable end is properly aligned and fully inserted into the square drive slot of the screw drive assembly. 3. Install the fore/aft motor (3) ensuring the square cable end is properly aligned and fully inserted into the square drive slot of the motor. 4. Install the motor retaining screws (1). Tighten the screws to 5 Nm (45 in. lbs.). 5. Install the flex drive cable. a. Install the flex drive cable into the seat frame assembly (2). Ensure the square cable end is properly aligned and fully inserted into the square drive slot of the screw drive assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9078 b. Install the flex drive cable into the fore/aft motor (1). Ensure the square cable end is properly aligned and fully inserted into the square drive slot of the motor assembly (3). 6. Position the flex drive cable cover (2) onto the seat track assembly (4). Ensure the cover slots are properly aligned and fully inserted onto the mounting tabs (3). 7. Pivot the cable cover towards the cable and onto the fore/aft motor (5). 8. Secure the cover to the motor with the retaining strap (1). 9. Connect the fore/aft motor electrical connector. 10. Install the power seat, See: Service and Repair/Seats, Front/Seat - Installation. 11. Verify proper power seat operation. Height Adjust Motor INSTALLATION 1. Screw the height adjust motor gearbox spindle (1) in or out as necessary until the motor retaining screws (3) and spindle screw (4) holes are aligned and all fasteners can be installed. 2. Position the height adjust motor and gearbox assembly (2) onto the seat track. 3. Install the motor retaining screws (3). Tighten the screws to 12 Nm (106 in. lbs.). 4. Install the height adjust motor gearbox spindle (1) retaining screw (4). Tighten the screw to 17 Nm (150 in. lbs.). 5. Connect the motor electrical connector. 6. Install the power seat, See: Service and Repair/Seats, Front/Seat - Installation. 7. Verify proper power seat operation. Tilt Motor INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9079 1. Screw the front tilt motor gearbox spindle (3) in or out as necessary until the motor retaining screws (4) and spindle screw (2) holes are aligned and all fasteners can be installed. 2. Position the front tilt motor and gearbox assembly (1) onto the seat track. 3. Install the motor retaining screws (4). Tighten the screws to 12 Nm (106 in. lbs.). 4. Install the front tilt motor gearbox spindle (3) retaining screw (2). Tighten the screw to 17 Nm (150 in. lbs.). 5. Connect the motor electrical connector. 6. Install the power seat, See: Service and Repair/Seats, Front/Seat Installation. 7. Verify proper power seat operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9083 Power Seat Switch: Diagrams Connector - (SEAT) 11 WAY SWITCH-SEAT-DRIVER - (SEAT) 11 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description Power Seat Switch: Description and Operation Power Seat Switch - Description DESCRIPTION The driver power seat can be adjusted in six different ways using the power seat switch. The power seat switch (2) is located on the lower outboard side of the seat cushion (1) on the seat cushion side shield (3). The power seat system incorporates a seat switch with a seat cushion control paddle. The individual components in the power seat switch assembly cannot be repaired. If the switch is damaged or inoperative, the entire power seat switch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description > Page 9086 Power Seat Switch: Description and Operation Power Seat Switch - Operation OPERATION When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 9087 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to POWER SEAT SWITCH CONTINUITY table. If not OK, replace the faulty power seat switch. If switch tests OK See: Testing and Inspection. POWER SEAT SWITCH CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the outboard seat cushion side shield (3). 3. Disconnect the power seat switch electrical harness connector (4). 4. Using a small flat bladed tool, gently release the four mounting tabs (1) that secure the power seat switch (2) and separate switch from side shield (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 9090 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch (2) onto the seat cushion side shield (3). Gently apply pressure to the switch until the four mounting tabs (1) are fully seated into place. 2. Connect the power seat switch electrical connector (4). 3. Install the seat cushion outboard side shield. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal Seat Back: Service and Repair Seat Back - Removal Front REMOVAL NOTE: See: Description and Operation/Seats, Front for detailed exploded views. NOTE: All call outs are in reference to the Driver Power exploded view unless otherwise noted. 1. Remove the seat from the vehicle. See: Service and Repair/Seats, Front/Seat - Removal. 2. Remove the lift handle cover (24 - Driver Manual) and mounting fasteners (26 - Driver Manual), if equipped. 3. Remove the lift handle (23 - Driver Manual), if equipped. 4. Carefully pry the side shield away from the recliner handle (26) and remove the retaining clip. 5. Remove the recliner handle. 6. Remove the rear fastener (31) from the outboard shield (25). 7. Starting at the rear of the outboard shield, carefully pry the side shield until the retainers disengage and slide the shield forward to remove. 8. Remove the seat buckle bolt and buckle (40). 9. Remove the rear fastener (31) from the inboard shield (42). 10. Starting at the rear of the inboard shield, carefully pry the side shield until the retainers disengage and slide the shield forward to remove. 11. Remove the airbag wiring harness (24) from the seat bottom, ensure the harness is completely removed from the bracket (26) and through recliner mechanism. 12. Remove the outboard and inboard seat back bolts (30). 13. Remove the seat back from the seat cushion assembly. Second Row REMOVAL 1. Remove the recliner handle cover and mounting fasteners. 2. Remove the recliner handle 3. Remove the folding seat handle cover, mounting fasteners and handle, if equipped. 4. Remove the outboard shield. 5. Remove the headrest and headrest guides. 6. Fold the seat flat and remove the seat back panel by carefully prying up on the panel until the retainers disengage. 7. For the 60 split seat only, remove the seat belt anchor mounting fastener. 8. Remove the seat cover clips and pull back to expose the inboard seat back mounting fasteners. NOTE: On the 40 split seat, the inboard mounting fasteners are located on the outside of the seat back frame. On the 60 split seat, they are located on the inside of the seat back frame which will require the seat back cushion/cover to be removed. See: . Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9095 9. Remove the inboard seat back mounting fasteners. 10. Remove the outboard seat back mounting fasteners. 11. Remove the cable attachment from the back steel panel. 12. Remove the seat back from the vehicle. Third Row REMOVAL 1. Remove the seat cover and cushion See: Seat Cover/Service and Repair/Seat Cushion Cover Removal. 2. Remove the retainers on the seat back gap hider from the rear storage box. 3. Remove the front seat back mounting fasteners (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9096 4. Remove the rear seat back mounting fasteners (1 and 2). 5. Remove the seat back from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9097 Seat Back: Service and Repair Seat Back - Installation Front INSTALLATION NOTE: See: Description and Operation/Seats, Front for detailed exploded views. NOTE: All call outs are in reference to the Driver Power exploded view unless otherwise noted. 1. Install the seat back to the seat cushion assembly. 2. Install the outboard and inboard seat back bolts (30) and torque to 40 N-m (29 ft. lbs.). 3. Install the airbag wiring harness (24) to the seat bottom. 4. Install the inboard shield. 5. Install the rear fastener (31) to the inboard shield (42). 6. Install the seat buckle bolt and buckle (40). Tighten to 45 N-m (33 ft. lbs.). 7. Install the outboard shield. 8. Install the rear fastener (31) to the outboard shield (25). 9. Install the recliner handle (26) retaining clip. 10. Install the recliner handle. 11. Install the lift handle (23 - Driver Manual), if equipped. 12. Install the mounting fasteners (26 - Driver Manual) and lift handle cover (24 - Driver Manual), if equipped. 13. Install the seat to the vehicle. See: Service and Repair/Seats, Front/Seat - Removal. Second Row INSTALLATION 1. Position the seat back frame to the seat adjuster assembly. 2. For the 40% seat back, install the inboard mounting fasteners. Tighten to 55 N-m (40 ft. lbs.). 3. For the 40% seat back, install the outboard mounting fasteners. Tighten to 30 N-m (22 ft. lbs.). 4. For the 60% seat back, install the inboard mounting fasteners. Tighten to 60 N-m (44 ft. lbs.). 5. For the 60% seat back, install the outboard mounting fasteners. Tighten to 30 N-m (22 ft. lbs.). 6. Install the seat back cushion/cover, if required. See: . 7. For the 60% seat back, place the seat belt and seat buckle into position. Tighten the mounting fastener to 49 N-m (36 ft. lbs.). 8. Install the cable attachment to the back steel panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9098 9. Install the outboard shield. 10. Install the recliner handle 11. Install the recliner handle mounting fasteners and cover. 12. Install the folding seat handle, mounting fasteners and cover, if equipped. 13. Install the headrest guides and headrest. Third Row INSTALLATION 1. Place the seat back into position in the vehicle. Make sure that the seat belts are position correctly. 2. Install the rear mounting fasteners (1 and 2). Tighten to 95 Nm (70 ft. lbs.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9099 3. Install the front mounting fasteners (1). Tighten to 95 Nm (70 ft. lbs.). 4. Install the retainers on the seat back gap hider to the rear storage box. 5. Install the seat cushion and cover See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9100 Seat Back: Service and Repair Seat Back Panel - Removal Front REMOVAL FOLD FLAT SEAT 1. Carefully disengage the clip retainers (2) by pulling up on the bottom and sides of the back panel. 2. Slide the back panel up to disengage the side retainers (3). 3. While lifting the bottom of the panel, slide the panel down and remove from the seat back disengaging the upper retainers (1). NON-FOLD FLAT SEAT 1. Carefully pull the bottom and sides of the panel upwards to disenge the lower clip retainers (2). 2. While lifting the bottom of the back panel, disengage the upper retainers (1) and remove the panel from the seat back. Second Row REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9101 1. Note the locations (1) of the retainers on the seat back panels (3) and armrest (2). CAUTION: Use care when removing the pushpins on the back panel from the seat back. Failure to do so will result in damage to the back panel. 2. Using a clip removal tool or equivalent, carefully disengage the retainers (2) that secure the seat back panel (1). 3. Remove the back panel from the seat. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9102 Seat Back: Service and Repair Seat Back Panel - Installation Front INSTALLATION FOLD FLAT SEAT 1. While lifting the bottom of the panel up, engage the upper retainers (1) to the seat back. 2. Engage the side retainers (3) to the seat and slide the back panel down into position. 3. Firmly seat the clip retainers (2) securing the back panel to the seat back. NON-FOLD FLAT SEAT 1. While lifting the bottom of the back panel, engage the upper retainers (1) to the seat back. 2. Firmly seat the lower clip retainers (2) securing the back panel to the seat back. Second Row INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back - Removal > Page 9103 1. Place the back panel (1) into position on the seat. 2. Engage the retainers (2) that secure the back panel to the seat. 3. Press firmly on the retainer locations (1), as shown above, to ensure proper engagement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-008-10 > Jun > 10 > Interior - Corrosion On 2nd Row Seat Frames Seat Bottom Frame: Customer Interest Interior - Corrosion On 2nd Row Seat Frames NUMBER: 23-008-10 GROUP: Body DATE: June 15, 2010 SUBJECT: Second Row Seat Revised Bracket Covers OVERVIEW: This bulletin involves the installation of 5 revised lower seat bracket covers and surface corrosion removal. MODELS: 2009-2010 (JC) Journey NOTE: This bulletin applies to vehicles built before February 02, 2010 (MDH0202XX). SYMPTOM/CONDITION: The customer may notice light surface corrosion of the seat frame. DIAGNOSIS: If the vehicle operator experiences the symptom/condition, perform the Repair Procedure. PARTS REQUIRED: NOTE: One 32oz bottle of IES Rust Raider will service 50 vehicles. REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-008-10 > Jun > 10 > Interior - Corrosion On 2nd Row Seat Frames > Page 9113 1. Fold the second row seat backs to the closed position and inspect the exposed seat frame locations (Fig. 1). 2. Inspect for light seat frame corrosion around the lower bracket. Was corrosion found (Fig. 2)? a. Yes>>> Neutralize all corrosion with IES Rust Raider 1840 or equivalent using an acid brush apply the material following manufacturers specifications and proceed to Step # 3. b. No>>> Proceed to Step # 3. NOTE: In (Fig. 2) the seat frame plastic trim has been removed for demonstration Purposes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-008-10 > Jun > 10 > Interior - Corrosion On 2nd Row Seat Frames > Page 9114 3. Install lower bracket cover (Fig. 3). 4. Fold seat back to the upright position. 5. Return the vehicle to the customer. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-008-10 > Jun > 10 > Interior Corrosion On 2nd Row Seat Frames Seat Bottom Frame: All Technical Service Bulletins Interior - Corrosion On 2nd Row Seat Frames NUMBER: 23-008-10 GROUP: Body DATE: June 15, 2010 SUBJECT: Second Row Seat Revised Bracket Covers OVERVIEW: This bulletin involves the installation of 5 revised lower seat bracket covers and surface corrosion removal. MODELS: 2009-2010 (JC) Journey NOTE: This bulletin applies to vehicles built before February 02, 2010 (MDH0202XX). SYMPTOM/CONDITION: The customer may notice light surface corrosion of the seat frame. DIAGNOSIS: If the vehicle operator experiences the symptom/condition, perform the Repair Procedure. PARTS REQUIRED: NOTE: One 32oz bottle of IES Rust Raider will service 50 vehicles. REPAIR PROCEDURE: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-008-10 > Jun > 10 > Interior Corrosion On 2nd Row Seat Frames > Page 9120 1. Fold the second row seat backs to the closed position and inspect the exposed seat frame locations (Fig. 1). 2. Inspect for light seat frame corrosion around the lower bracket. Was corrosion found (Fig. 2)? a. Yes>>> Neutralize all corrosion with IES Rust Raider 1840 or equivalent using an acid brush apply the material following manufacturers specifications and proceed to Step # 3. b. No>>> Proceed to Step # 3. NOTE: In (Fig. 2) the seat frame plastic trim has been removed for demonstration Purposes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-008-10 > Jun > 10 > Interior Corrosion On 2nd Row Seat Frames > Page 9121 3. Install lower bracket cover (Fig. 3). 4. Fold seat back to the upright position. 5. Return the vehicle to the customer. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal Seat Cover: Service and Repair Seat Back Cover - Removal Second Row REMOVAL 1. Remove the folding seat handle cover, mounting fasteners and handle from the seat back. 2. Remove the seat belt trim, if required. 3. Remove the headrest and headrest guides. 4. Fold the seat back down flat. 5. For the 60 split seat only, remove the seat belt anchor bolt. 6. Remove the back panel from the seat back. See: Seat Back/Service and Repair/Seat Back Panel - Removal. 7. Release the seat cover clips from the seat back. 8. Carefully pull the seat cover and foam away from the seat back frame. 9. If required, feed the seat belt through the seat cover. 10. Carefully pull the cover off of the foam, cutting any hog rings and discarding. Front REMOVAL NOTE: See: Description and Operation/Seats, Front for a detailed exploded view of the seats. NOTE: All call outs are in reference to the Driver Power exploded view unless otherwise noted. 1. Remove the seat from the vehicle. See: Service and Repair/Seats, Front/Seat - Removal. 2. Remove the seat back. See: Seat Back/Service and Repair/Seat Back - Removal/Front. 3. Remove the lumbar handle cover (23). 4. Remove the retaining fastener (22) and remove the handle (21). 5. Remove the back panel from the seat back. See: Seat Back/Service and Repair/Seat Back Panel Removal. 6. Remove the J-clips and pushpins on the seat back cover from the frame. 7. Remove the side airbag (SAB) mounting nuts. 8. Disconnect the SAB wiring connector. 9. Remove the SAB from the seat cover. 10. Remove the inner inboard shield (41). 11. Remove the inner outboard shield (28). 12. Remove the headrest guides (12). See: Head Rest/Service and Repair/Headrest Sleeve - Removal. 13. Starting from the bottom rear of the seat back, carefully pull seat cover off seat cushion to expose hog rings. 14. Cut hog rings and discard. 15. Remove the cover from the seat back assembly. 16. Remove the seat cushion foam, if required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9126 Seat Cover: Service and Repair Seat Back Cover - Installation Second Row INSTALLATION 1. Carefully install the cover to the foam, installing any hog rings. 2. If required, feed the seat belt through the seat cover. 3. Position the seat cover and foam to the seat back frame. 4. Install the seat cover clips to the seat back. 5. Install the seat back panel. See: Seat Back/Service and Repair/Seat Back Panel - Installation. 6. For the 60 split seat only, install the seat belt anchor bolt. Tighten to 49 N-m (36 ft. lbs.). 7. Fold the seat back up. 8. Install the headrest guides and headrest. 9. Install the seat belt trim, if required. 10. Install the folding seat handle, mounting fasteners and cover to the seat back. Front INSTALLATION NOTE: See: Description and Operation/Seats, Front for a detailed exploded view of the seats. NOTE: Do not reuse the recliner assembly attaching bolts. 1. Position cover on the top of seat back. 2. Carefully roll cover down to the area that hog rings are to be installed. 3. Install the side airbag (SAB) to the seat back cover. 4. Connect the SAB wiring connector. 5. Install the SAB mounting fasteners. 6. Engage the J-clip retainers to the back frame assembly. 7. Install hog rings. 8. Roll cover downward. 9. Engage the J-clip retainer to the seat frame. 10. Install lumbar handle, if equipped. 11. Install the seat back panel. See: Seat Back/Service and Repair/Seat Back Panel - Installation 12. Install headrest guides. See: Head Rest/Service and Repair/Headrest Sleeve - Installation. 13. Install seat back to seat cushion. See: Seat Back/Service and Repair/Seat Back - Installation/Front. 14. Install the seat to the vehicle. See: Service and Repair/Seats, Front/Seat - Installation. 15. Check seat back and headrest operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9127 Seat Cover: Service and Repair Seat Cushion Cover - Removal Front REMOVAL NOTE: See: Description and Operation/Seats, Front for a detailed exploded view of the seats. 1. Remove seat from vehicle.See: Service and Repair/Seats, Front/Seat - Removal 2. Remove the wiring harness from the seat pan. 3. Remove four seat pan fasteners (1). 4. Remove the seat pan from the adjuster assembly. 5. Remove the J-clips securing the seat cover to the seat pan, if required. 6. Starting at the rear of the seat cushion, carefully pull seat cover (3) down towards the front. 7. Cut and discard hog rings. 8. Remove the seat cover from the foam. Third Row REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9128 1. Remove the rear storage box. See: Interior Moulding / Trim/Utility Storage Compartment/Service and Repair/Rear Storage Box - Removal. 2. Lift front edge of the third row seat until retainers (5) disengage. 3. With the help of an assistant, carefully pry up on the hooks (4) while the seat cushion is being pressed towards the seat back. 4. While lifting up on the hooks, pull the seat cushion out towards the front of the vehicle and remove the seat cushion. 5. Disengage J-clips from seat cushion. 6. Carefully remove the seat cover from the cushion, removing any hog rings and discarding. Second Row REMOVAL NOTE: Only the 40 split seat must be removed to replace the seat cushion. 1. For the 40 split seat only, remove the seat from the vehicle. See: Service and Repair/Seats, Front/Seat - Removal. 2. Remove the seat recliner handle cover and fastener. 3. Remove the seat recliner handle. 4. Remove the seat adjuster handle cover and fastener. 5. Remove the seat adjuster handle. 6. Remove the seat side shields. 7. Remove the outboard seat bolt securing the seat cushion to the seat frame. 8. For the 40 split seat only, remove the inboard seat cushion mounting fastener. 9. Pull the release latch and push up on seat cushion to separate from the seat frame. 10. Remove the cable assembly from the seat cushion. 11. Remove the gas strut from the seat cushion, if equipped. 12. Remove the cushion from the seat frame. 13. Unzip the cover from the cushion. 14. Carefully pull the seat cover off of the seat cushion, cutting any hog rings and discarding them, if required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9129 Seat Cover: Service and Repair Seat Cushion Cover - Installation Front INSTALLATION NOTE: See: Description and Operation/Seats, Front for a detailed exploded view of the seats. 1. Install the heated seat element (2) to the seat cushion, if required. 2. Slide the seat cover (3) over the front of the cushion. 3. Install hog rings as the cover is slid over the cushion. 4. Place the seat cushion into position on the seat pan. 5. Install the J-clips securing the seat cushion to the seat pan. 6. Install the seat pan and cushion to the adjuster assembly. 7. Install the mounting fasteners and torque to 12.5 N-m (9 ft. lbs.). 8. Install the seat to the vehicle. See: Service and Repair/Seats, Front/Seat - Installation. Third Row INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9130 1. Carefully install the seat cover to the cushion, installing any hog rings required. 2. Engage J-clips to seat cushion. 3. Place the third row seat cushion (1) into position. 4. Press the seat cushion back (2) and under the seat back. 5. Ensure the seat retaining hooks (4) slide under the body side hooks. 6. Firmly depress the front of the seat cushion down, ensuring that the seat retainers (5) engage. 7. Install the rear storage box. See: Interior Moulding / Trim/Utility Storage Compartment/Service and Repair/Rear Storage Box - Installation Second Row INSTALLATION 1. Carefully pull the seat cover over the seat foam, installing any hog rings, if required. 2. Zip the cover on to the foam. 3. Install the cushion to the seat frame. 4. Install the gas strut to the seat cushion, if equipped. 5. Install the cable assembly to the seat cushion. 6. Ensure the seat cushion is latched into the seat frame. 7. Install the outboard seat bolt securing the seat cushion to the seat frame. Tighten to 30 N-m (22 ft. lbs.). 8. Install the inboard seat bolt, if required. 9. Install the seat side shields. 10. Install the seat recliner handle. 11. Install the seat recliner handle fastener and cover. 12. Install the seat adjuster handle. 13. Install the seat adjuster handle fastener and cover. 14. Install the seat to the vehicle, if required. See: Service and Repair/Seats, Front/Seat - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Side Shields - Removal Seat Cushion: Service and Repair Seat Cushion Side Shields - Removal REMOVAL NOTE: See: Description and Operation/Seats, Front for detailed exploded views. NOTE: All call outs are in reference to the Driver Power exploded view unless otherwise noted. 1. Remove the seat from the vehicle. See: Service and Repair/Seats, Front/Seat - Removal. 2. Remove the lift handle cover (24 - Driver Manual) and mounting fasteners (26 - Driver Manual), if equipped. 3. Remove the lift handle (23 - Driver Manual), if equipped. 4. Remove the recliner handle retainer and handle (26). 5. Remove the seat belt buckle bolt and buckle (40). 6. Remove the rear fastener on the outboard shield (25). 7. Remove the rear fastener on the inboard shield (42). 8. Remove the appropriate side shield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Side Shields - Removal > Page 9135 Seat Cushion: Service and Repair Seat Cushion Side Shields - Installation INSTALLATION NOTE: See: Description and Operation/Seats, Front for detailed exploded views. NOTE: All call outs are in reference to the Driver Power exploded view unless otherwise noted. 1. Install the side shield. 2. Install the rear fastener on the inboard shield (42). 3. Install the rear fastener on the outboard shield (25). 4. Install the seat belt buckle bolt and buckle (40). 5. Install the recliner handle retainer and handle (26). 6. Install the lift handle (23 - Driver Manual), if equipped. 7. Install the lift handle cover (24 - Driver Manual) and mounting fasteners (26 - Driver Manual), if equipped. 8. Install the seat to the vehicle. See: Service and Repair/Seats, Front/Seat Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Back Heater Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Back Heater > Page 9140 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Back Heater > Page 9141 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Back Heater > Page 9142 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way Seat Heater: Diagrams Driver Seat Back Heater (Component Side) (Seat Back) 2 Way Connector (COMPONENT SIDE) - (SEAT BACK) 2 WAY HEATER-SEAT BACK-DRIVER (COMPONENT SIDE) - (SEAT BACK) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9145 Seat Heater: Diagrams Driver Seat Back Heater (Seat Cushion) 2 Way Connector - (SEAT CUSHION) 2 WAY HEATER-SEAT BACK-DRIVER - (SEAT CUSHION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9146 Seat Heater: Diagrams Passenger Seat Back Heater (Component Side) (Seat Back) 2 Way Connector (COMPONENT SIDE) - (SEAT BACK) 2 WAY HEATER-SEAT BACK-PASSENGER (COMPONENT SIDE) - (SEAT BACK) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9147 Seat Heater: Diagrams Passenger Seat Back Heater (Seat) 2 Way Connector - (SEAT) 2 WAY HEATER-SEAT BACK-PASSENGER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9148 Seat Heater: Diagrams Driver Seat Back Heater (Component Side) (Seat Back) 2 Way Connector (COMPONENT SIDE) - (SEAT BACK) 2 WAY HEATER-SEAT BACK-DRIVER (COMPONENT SIDE) - (SEAT BACK) 2 WAY Driver Seat Back Heater (Seat Cushion) 2 Way Connector - (SEAT CUSHION) 2 WAY HEATER-SEAT BACK-DRIVER - (SEAT CUSHION) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9149 Passenger Seat Back Heater (Component Side) (Seat Back) 2 Way Connector (COMPONENT SIDE) - (SEAT BACK) 2 WAY HEATER-SEAT BACK-PASSENGER (COMPONENT SIDE) - (SEAT BACK) 2 WAY Passenger Seat Back Heater (Seat) 2 Way Connector - (SEAT) 2 WAY HEATER-SEAT BACK-PASSENGER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9150 Driver Seat Cushion Heater (Component Side) (Seat Cushion) 2 Way Connector (COMPONENT SIDE) - (SEAT CUSHION) 2 WAY HEATER-SEAT CUSHION-DRIVER (COMPONENT SIDE) - (SEAT CUSHION) 2 WAY Driver Seat Cushion Heater (Seat) 2 Way Connector - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9151 HEATER-SEAT CUSHION-DRIVER - (SEAT) 2 WAY Passenger Seat Cushion Heater (Component Side) (Seat Cushion) 2 Way Connector (COMPONENT SIDE) - (SEAT CUSHION) 2 WAY HEATER-SEAT CUSHION-PASSENGER (COMPONENT SIDE) - (SEAT CUSHION) 2 WAY Passenger Seat Cushion Heater (Seat) 2 Way Connector - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Back Heater (Component Side) (Seat Back) 2 Way > Page 9152 HEATER-SEAT CUSHION-PASSENGER - (SEAT) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description Seat Heater: Description and Operation Heated Seats - Description DESCRIPTION MODULE-ASBM Vehicles with the heated seat option can be visually identified by the two heated seat switches (1) located in the center stack of the instrument panel. The switches are located on the outer edges of the Accessory Switch Bank Module (ASBM). The ASBM is located just below the vents and just above the heater and air conditioner controls in the center stack area of the instrument panel. The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system includes the following major components: - Heated Seat Elements - Four heated seat elements are used per vehicle. Two heated seat elements are integral to each seat, one in the seat back and the other in the seat cushion. - Heated Seat Module - One heated seat module is used per vehicle. The Heated Seat Module is mounted under the Driver front seat. This module contains the control logic and software for the front heated seat system. The module communicates on the Local Interface Network (LIN) data bus. - Heated Seat Switches - Two heated seat switches are used per vehicle, one for each heated seat. Both switches are integral to the ASBM mounted in the instrument panel center stack. - Instrument Cluster (CCN) - The instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) utilizes integrated software and information carried on the LIN data bus. The CCN serves as the link between the heated seat switches and the heated seat module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 9155 Seat Heater: Description and Operation Heated Seats - Operation OPERATION The heated seat system operates on battery current received through a fuse in the Totally Integrated Power Module (TIPM). Fused ignition switch output (Run) circuits are used, so that the heated seat system will only operate when the ignition switch is in the ON position. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except ON. A Heated Seat Module (2) is used to control the heated seat system. The module is located under the driver front seat mounted to the seat pan (4). The heated seat module responds to heated seat switch messages and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switches (1) are depressed a switch status message is sent to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CNN via the LIN data bus. The CNN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The heated seat module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after 26 minutes of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting also turns off automatically after 30 minutes. The module will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 9156 Seat Heater: Description and Operation Heater Pad - Description DESCRIPTION Vehicles equipped with the optional heated seat system have two carbon fiber heated seat elements located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat elements consist of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated seat elements are captured between the leather trim cover and the seat cushion assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element assembly must be installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 9157 Seat Heater: Description and Operation Heater Pad - Operation OPERATION One end of the heated seat element is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element by the heated seat module. The heated seat module will energize the heated seat element when the heated seat switch is depressed in the LOW or HIGH position. As electrical current passes through the heated seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System Seat Heater: Testing and Inspection Heated Seat System HEATED SEAT SYSTEM In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 9160 Seat Heater: Testing and Inspection Heater Pad HEATED SEAT ELEMENT Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors for the heating elements are located under the seat. NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat element electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.0 - 5.5 ohms for a seat cushion element and 4.0 - 6.0 ohms for a seat back element. If OK, See: Heated Seat System. If not OK, replace the inoperative heated seat element. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal Seat Heater: Service and Repair Heater Pad - Removal REMOVAL NOTE: The factory installed heating element can be removed from foam cushion by carefully peeling the element off along the adhesive lines. NOTE: Heated seat cushion shown, heated seat back similar. 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat cushion trim cover, See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal or seat back trim cover, See: Seat Cover/Service and Repair/Seat Back Cover - Removal. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Peel the heater element off the foam pad, being careful not to remove excessive foam in the process. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal > Page 9163 Seat Heater: Service and Repair Heater Pad - Installation INSTALLATION CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. NOTE: Heated seat cushion shown, heated seat back similar. 1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick on foam pad directly where the original element was placed (there will be adhesive marks on the foam outlining factory installed element)(1). 2. Connect the new heating element electrical connectors (3 AND 4). 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion trim cover, See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation or seat back trim cover, See: Seat Cover/Service and Repair/Seat Back Cover - Installation. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. The factory installed heater element should be completely removed from the system and discarded. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 9167 Seat Heater Control Module: Diagrams Connector - (SEAT) 10 WAY MODULE-HEATED SEATS - (SEAT) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located under the driver front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan (4). The module can be accessed from under the Driver seat with the seat in the full back and up position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 9170 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN) via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate Diagnostic Trouble Code (DTC). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 9171 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the driver front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 9174 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description DESCRIPTION Two heated seat switches are located in the center stack of the instrument panel. The switches are located on the outer edges of the Accessory Switch Bank Module (ASBM). The ASBM (3) is located just below the radio (1) and just above the heater and air conditioner controls (2) in the center stack area of the instrument panel. If either of the switches is damaged or inoperative the complete ASBM assembly must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9179 Each heated seat switch (4) provides a resistor-multiplexed signal to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). Amber Light Emitting Diodes (LEDs) on the outside edge of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete ASBM assembly must be replaced, See: Service and Repair/Heated Seat Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9180 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation OPERATION The heated seat switches (4) are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9181 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The heated seat switches are integral to the Accessory Switch Bank Module (ASBM) and cannot be serviced separately. The complete ASBM assembly must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel, See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the four screws (1) that secure the ASBM (2) to the back of the instrument panel center bezel (3) and remove the ASBM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9184 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION NOTE: There are different Accessory Switch Bank Module (ASBM) configurations available based on the option content of the vehicle. Ensure the ASBM being installed matches the vehicle options. 1. Position the ASBM (2) onto the back of the instrument panel center bezel (3). 2. Install the four screws (1) that secure the ASBM to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel, See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Power Seat Track - Removal Seat Track: Service and Repair Power Seat Track - Removal REMOVAL WARNING: Disable the airbag system before attempting any component diagnosis or service of the front seats, when equipped with front seat air bags. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Driver seat shown in illustrations. Passenger seat similar. 1. Position the seat so that the heads of the bolts which secure the rear of the seat riser to the track can be accessed. 2. Remove the seat from the vehicle and place it on a workbench See: Service and Repair/Seats, Front/Seat - Removal. 3. Remove the inboard seat cushion side shield See: Seat Cushion/Service and Repair/Seat Cushion Side Shields - Removal. 4. Remove the push-pin retainers (1) that secure the two elastic straps (4) of the seat bottom closeout (3) to the bottom of the seat cushion frame (2) and remove the closeout. NOTE: Heated seat shown. Non-heated seat similar. 5. If equipped, remove the heated seat module (4) from the bottom of the seat cushion frame (3). 6. Disconnect the wire harness connectors from the power seat motors (1) and the seat track position sensor (8) and remove the wire harness (7) from the bottom of the seat cushion frame and the seat riser (9). 7. If required, remove the seat track position sensor from the seat track. 8. Remove the bolt (2) that secures the four seat track mounting brackets (3) to the bottom of the seat cushion frame. 9. Disengage the seat track mounting brackets from the bottom of the seat cushion frame and remove the seat track assembly (6) from the frame. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Power Seat Track - Removal > Page 9189 10. If required, remove the wire harness retaining bracket (4) from the bottom of the seat riser (2). 11. Remove the two nuts (1) and the two bolts (3) that secure the seat riser to the seat track and remove the riser. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Power Seat Track - Removal > Page 9190 Seat Track: Service and Repair Power Seat Track - Installation INSTALLATION NOTE: Driver seat shown in illustrations. Passenger seat similar. 1. Position the seat riser (2) to the seat track and install the retaining two nuts (1) and bolts (3). Tighten the nuts and bolts to 48 Nm (35 ft. lbs.). 2. Install the wire harness retaining bracket (4) onto the seat riser. NOTE: Heated seat shown. Non-heated seat similar. 3. If removed, install the seat track position sensor (8). 4. Position the seat track assembly (6) to the bottom of the seat cushion frame (5). Make sure the seat track is properly located and that the plastic isolators are correctly installed. 5. Engage the four seat track mounting brackets (3) to the bottom of the seat cushion frame and install the retaining bolts (2). Tighten the bolts to 28 Nm (21 ft. lbs.). 6. Install the wire harness (7) to the bottom of the seat cushion frame and to the seat riser (9) and connect the wire harness connectors to the power seat motors (1) and the seat track position sensor. 7. If equipped, install the heated seat module (4) onto the bottom of the seat cushion frame. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Power Seat Track - Removal > Page 9191 8. Position the seat bottom closeout (3) to the rear of the seat and install the push-pin retainers (1) that secure the two elastic straps (4) to the bottom of the seat cushion frame (2). 9. Install the inboard seat cushion side shield See: Seat Cushion/Service and Repair/Seat Cushion Side Shields - Installation. 10. Install the seat into the vehicle See: Service and Repair/Seats, Front/Seat - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Power Seat Track - Removal > Page 9192 Seat Track: Service and Repair Seats, Second Row Seat Track Adjuster - Removal REMOVAL 1. Remove the seat cushion. See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Remove the rear plastic shield fasteners and shields. 3. Remove the bottom plastic shield by carefully prying up on the shield until the retainers disengage. 4. Remove the cables and cable assemblies. 5. Remove the frame to adjuster fasteners and separate. 6. Remove the adjuster latch mounting nuts and remove the latch. Seat Track Adjuster - Installation INSTALLATION 1. Install the adjuster latch mounting nuts and install the latch. 2. Position the frame to the adjuster assembly. 3. Install the frame to adjuster fasteners. Tighten to 30 N-m (22 ft. lbs.). 4. Install the cables and cable assemblies. 5. Install the bottom plastic shield ensuring the retainers engage. 6. Install the rear plastic shield shields and fasteners. 7. Install the seat cushion and cover See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch - Removal > Page 9198 Door Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch - Installation INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Install door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 9203 Hood Sensor/Switch (For Alarm): Diagrams Connector - (FRONT END MODULE) 2 WAY SWITCH-HOOD AJAR - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Security System (VTSS) for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the right inner fender shield near the fender ledge in the engine compartment. The underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 9206 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and it will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard-wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (3) from the switch connector receptacle. 4. From the top of the hood ajar switch mounting bracket (2), squeeze the two switch latch tabs together and pull the switch (1) upward through the hole in the mounting bracket. 5. Remove the hood ajar switch from the mounting bracket and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 9209 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation SWITCH NOTE: Self-adjustment of the hood ajar switch is a one-time feature. If the switch is damaged, ineffective, removed or requires readjustment, it must be replaced with a new unit. 1. Position the hood ajar switch (1) above the hole in the mounting bracket (2). 2. Press the switch into the mounting hole until the integral switch latch tabs lock it into place. 3. Connect the harness connector (3) to the switch connector receptacle. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch > Page 9214 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 9217 Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C2 (Front Door) 10 Way Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 9218 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Except Base) (Front Door) 10 Way Connector (EXCEPT BASE) - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Front Door) 14 Way > Page 9219 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Base) (Front Door) 8 Way Connector (BASE) - (FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (BASE) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9220 Power Door Lock Switch: Testing and Inspection DIAGNOSIS AND TESTING VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: - Touch other test light lead to battery feed B+ terminal. - If test light comes on, the wiring circuit between the battery and switch is functional. - If test light does not come on, check for a blown fuse. Refer to Wiring Diagrams for circuit information. DOOR LOCK SWITCH NOTE: Vehicles equipped with the auto-express feature for power windows, the local interface network (LIN) controls the lock, mirror and window features. Remove the non-express switch from its mounting location. Using an ohmmeter, refer to the DOOR LOCK SWITCH CONTINUITY table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. DOOR LOCK SWITCH CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 9223 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Connect switch wire connector. 2. Install the switch by snapping into place. 3. Connect the battery negative remote cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 9228 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Connect switch wire connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9232 Power Seat Switch: Diagrams Connector - (SEAT) 11 WAY SWITCH-SEAT-DRIVER - (SEAT) 11 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description Power Seat Switch: Description and Operation Power Seat Switch - Description DESCRIPTION The driver power seat can be adjusted in six different ways using the power seat switch. The power seat switch (2) is located on the lower outboard side of the seat cushion (1) on the seat cushion side shield (3). The power seat system incorporates a seat switch with a seat cushion control paddle. The individual components in the power seat switch assembly cannot be repaired. If the switch is damaged or inoperative, the entire power seat switch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description > Page 9235 Power Seat Switch: Description and Operation Power Seat Switch - Operation OPERATION When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 9236 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to POWER SEAT SWITCH CONTINUITY table. If not OK, replace the faulty power seat switch. If switch tests OK See: Seats/Testing and Inspection. POWER SEAT SWITCH CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the outboard seat cushion side shield (3). 3. Disconnect the power seat switch electrical harness connector (4). 4. Using a small flat bladed tool, gently release the four mounting tabs (1) that secure the power seat switch (2) and separate switch from side shield (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 9239 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch (2) onto the seat cushion side shield (3). Gently apply pressure to the switch until the four mounting tabs (1) are fully seated into place. 2. Connect the power seat switch electrical connector (4). 3. Install the seat cushion outboard side shield. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description DESCRIPTION Two heated seat switches are located in the center stack of the instrument panel. The switches are located on the outer edges of the Accessory Switch Bank Module (ASBM). The ASBM (3) is located just below the radio (1) and just above the heater and air conditioner controls (2) in the center stack area of the instrument panel. If either of the switches is damaged or inoperative the complete ASBM assembly must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9244 Each heated seat switch (4) provides a resistor-multiplexed signal to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN). Amber Light Emitting Diodes (LEDs) on the outside edge of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete ASBM assembly must be replaced, See: Service and Repair/Heated Seat Switch - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9245 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation OPERATION The heated seat switches (4) are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9246 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The heated seat switches are integral to the Accessory Switch Bank Module (ASBM) and cannot be serviced separately. The complete ASBM assembly must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel, See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the four screws (1) that secure the ASBM (2) to the back of the instrument panel center bezel (3) and remove the ASBM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9249 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION NOTE: There are different Accessory Switch Bank Module (ASBM) configurations available based on the option content of the vehicle. Ensure the ASBM being installed matches the vehicle options. 1. Position the ASBM (2) onto the back of the instrument panel center bezel (3). 2. Install the four screws (1) that secure the ASBM to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel, See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 9253 Sunroof / Moonroof Switch: Diagrams Connector - (HEADLINER) 4 WAY SWITCH-SUNROOF - (HEADLINER) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced, See: Service and Repair/Sunroof Switch Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description > Page 9256 Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 9257 Sunroof / Moonroof Switch: Testing and Inspection SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the overhead console assembly, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. POWER SUNROOF SWITCH CONTINUITY TABLE Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using a suitable flat bladed tool, release the mounting tabs from the sides of the sunroof control switch and pull the switch out of the overhead console assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal > Page 9260 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Installation INSTALLATION 1. Insert the sunroof control switch into the overhead console assembly. Push the switch until it is securely held in place by the mounting tabs. 2. Install the overhead console, See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations SOUND DEADENER LOCATIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9264 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9265 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9266 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9267 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Spare Tire Carrier Winch - Removal Spare Tire Carrier: Service and Repair Spare Tire Carrier Winch - Removal REMOVAL 1. Access and remove the spare tire. 2. Remove the screw and two nuts securing the winch to the body floor pan. 3. Remove the winch from the jack storage compartment carefully extracting the cable and retainer through the access hole. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Spare Tire Carrier Winch - Removal > Page 9272 Spare Tire Carrier: Service and Repair Spare Tire Carrier Winch - Installation INSTALLATION 1. Route the winch cable and retainer down through the access hole in the jack storage compartment. 2. Position the spare tire winch on the floor pan, over the mounting studs. 3. Install the screw and two nuts securing the winch to the body floor pan. First, tighten the screw to 7 Nm (62 in. lbs.), then tighten the nuts to 7 Nm (62 in. lbs.). 4. Install the spare tire. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise Cowl Moulding / Trim: Customer Interest Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 9283 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 9284 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise Cowl Moulding / Trim: All Technical Service Bulletins Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 9290 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 23-027-08 > Sep > 08 > Body - Cowl Panel Gap At Windshield/Wind Noise > Page 9291 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 9292 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 23-027-08 Date: 080906 Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 9293 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 9294 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-027-08 Date: 080906 Body - Cowl Panel Gap At Windshield/Wind Noise NUMBER: 23-027-08 GROUP: Body DATE: September 6, 2008 SUBJECT: Cowl Panel Screen Gapping From Windshield OVERVIEW: This bulletin involves inspection and installation of an additional cowl screen push-pin. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 9295 MODELS: 2009 (JC) Journey NOTE: This bulletin applies to vehicles between January 2, 2008 (MDH0102XX) and April 30, 2008 (MDH0430XX). SYMPTOM/CONDITION: The customer may experience one or more of the following conditions: ^ Wind noise from lower windshield and cowl screen panel center area at highway speed. ^ Cowl screen panel gapping or warping from windshield at center area. DIAGNOSIS: 1. Inspect the cowl screen panel center section, for gapping from the windshield. 2. Is the gap 2 mm (0.078 in.) or greater? a. Yes >>> Perform the Repair Procedure. b. No >>> Repair procedure does not apply. Further diagnosis required. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove the inner cowl screen from the vehicle. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > REMOVAL. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 9296 2. Drill a 13 mm (0.511 in.) hole in the inner cowl panel lower screen at the location shown (Fig 1). 3. Cut and remove a 14 mm (0.551 in.) section of foam from the airbox at the location shown (Fig. 2). 4. Install the inner cowl panel lower screen but do not install the wiper arms or outer cowl panel top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 9297 5. Drill a 6.5 mm (0.256 in.) hole in the airbox flange at center of cowl screen hole (Fig. 3). 6. Install push pin p/n 06501590 through the cowl screen into the airbox hole. 7. Install the wiper arms and cowl top screen. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 23 - BODY > EXTERIOR > COVER, Cowl Panel, Inner > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Inner Cover - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). Remove the cowl top screen (3). 3. Remove the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Remove the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° clockwise to release the screen. 5. Remove the cowl screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 9300 Cowl Moulding / Trim: Service and Repair Cowl Panel Inner Cover - Installation INSTALLATION 1. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place. 2. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 3. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 9301 Cowl Moulding / Trim: Service and Repair Cowl Panel Outer Cover - Removal REMOVAL 1. Open the hood. 2. Remove the two push-pins (1) securing the cowl top screen at the ends. Remove the remaining push-pins (2). 3. Remove the cowl top screen (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Inner Cover - Removal > Page 9302 Cowl Moulding / Trim: Service and Repair Cowl Panel Outer Cover - Installation INSTALLATION 1. Position the cowl top screen (3). 2. Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Outer Belt Molding - Removal Rear Door Window Glass Weatherstrip: Service and Repair Outer Belt Molding - Removal REMOVAL 1. Lower the window to the full down position. 2. Remove the rear door trim panel. See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel Removal. 3. Remove the front and rear mounting fasteners. 4. Remove the rear door belt molding (2) by carefully pulling up on the molding and remove from the rear door (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Outer Belt Molding - Removal > Page 9308 Rear Door Window Glass Weatherstrip: Service and Repair Outer Belt Molding - Installation INSTALLATION 1. Install the rear door belt molding (2) to the rear door (3). 2. Install the front and rear mounting fasteners. 3. Install the rear door trim panel. See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel Installation. 4. Verify proper window operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Removal REMOVAL 1. Remove sunroof glass panel See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal > Page 9313 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Installation INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9318 Cruise Control Switch: Diagrams Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL - (STEERING WHEEL) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 9321 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. 2. Install speed control switch mounting screws (4) and tighten screws to 1.6 Nm (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3). 4. Install horn switch (2) to steering wheel. 5. Install horn switch mounting screws (3) and tighten screws to 8 Nm (71 ins. lbs.). 6. Connect electrical connector to horn switch. 7. Install driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag Installation. 8. Connect negative battery cable, tighten nut to 4.5 Nm (40 in. lbs.). 9. Verify vehicle and system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9326 Cruise Control Switch: Diagrams Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL - (STEERING WHEEL) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 9329 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. 2. Install speed control switch mounting screws (4) and tighten screws to 1.6 Nm (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3). 4. Install horn switch (2) to steering wheel. 5. Install horn switch mounting screws (3) and tighten screws to 8 Nm (71 ins. lbs.). 6. Connect electrical connector to horn switch. 7. Install driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag Installation. 8. Connect negative battery cable, tighten nut to 4.5 Nm (40 in. lbs.). 9. Verify vehicle and system operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description Audible Warning Device: Description and Operation Chime/Buzzer - Description DESCRIPTION The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the circuit board of the instrument cluster also known as the Cab Compartment Node (CCN) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The CCN also includes the necessary hardware and software to serve as the vehicle's electronic body control module. The electromechanical transducer generates chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based CCN utilizes electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus along with hard-wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the CCN allow it to control the audible outputs that are produced through its on-board transducer and relay. The CCN is capable of producing the following audible outputs: - Slow Rate Repetitive Click - Repeated click tones that are issued at a slow rate of about 90 clicks per minute. - Fast Rate Repetitive Click - Repeated click tones that are issued at a fast rate of more than about 180 clicks per minute. Single Chime Tone - A single chime tone. - Continuous Repetitive Chime Tone - Repeated chime tones that are issued continuously. Hard-wired circuitry connects the CCN and the various chime warning system switch and sensor inputs to their modules and to each other through the electrical system of the vehicle. These hard-wired circuits are integral to several wire harnesses that are routed throughout the vehicle and they are retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system, and to the CCN through a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, procedures for proper wire and connector repair, further details on wire harness routing and retention, and pin-out and location views for the various wire harness connectors, splices, and grounds. The chime warning system circuits and components cannot be adjusted or repaired. If the CCN circuitry, the on-board transducer, or the relay is damaged or ineffective, the instrument cluster assembly must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9335 Audible Warning Device: Description and Operation Chime/Buzzer - Operation OPERATION DOOR AJAR CHIME The Cab Compartment Node (CCN) will sound an audible chime when the key is in the ignition and the driver's door is open. This is to prevent partial closing of vehicle doors. An audible chime will sound when the vehicle begins to move and the transmission range indicator display will indicate DOOR. ENHANCED SEAT BELT REMINDER If all the following are met after sixty seconds with the engine ON, then the enhanced seat belt reminder feature will be activated. - Driver seat belt is unbuckled for ten seconds or more. - Vehicle speed is greater than five mph (8 km/h). - The gear positioning is not in REVERSE (except in MTX vehicles where the reverse position cannot be detected). The seat belt indicator will periodically blink, accompanied with a continuous chime for approximately ninety-six seconds or until the driver seat belt is buckled. When the enhanced seat belt feature is not initiated or if the feature is disabled, the seat belt indicator will be turned ON continuously until the driver seat belt is buckled. In the same ignition cycle, if the seat belt is again unbuckled for more than ten seconds with the vehicle speed greater than five mph (8 km/h), the enhanced seat belt reminder feature will again be initiated. The enhanced seat belt reminder feature is customer programmable and can be enabled/disabled with the use of a Scan Tool, or by the customer completing a sequence of steps. CUSTOMER PROGRAMMING OF ENHANCED SEAT BELT REMINDER FEATURE 1. With the ignition not in RUN or START, buckle the driver seat belt. 2. Turn the ignition switch to the RUN or START position and wait for the seat belt reminder check to be completed. 3. Unbuckle and then re-buckle the driver seat belt causing the indicator to go ON and OFF three or more times ending with the seat belt buckled. 4. Return the ignition switch back to a non-RUN or no-START position (the feature will toggle from the current status) and a confirmation chime will sound indicating to the customer the proper sequence to enable/disable the feature was performed. EXTERIOR LAMPS LEFT ON An audible chime tone that indicates the exterior lamps were left on. FASTEN SEAT BELTS At power up, the instrument cluster will conduct a seat belt lamp bulb check. If the driver side seat belt buckle is unbuckled during the bulb check, an accompanying chime will sound within the duration of the bulb check. KEY LEFT IN IGNITION An audible chime tone that indicates the key was left in ignition. SINGLE WARNING CHIME After a bulb check at power-up, if any of the following indicators are still activated, the CCN will sound a single chime tone. ABS, Air Bag, Check Engine, Charging System, Engine Temperature, Low Fuel (after 10 seconds for accurate fuel information), and BRAKE (if speed is greater than 2 mph). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 9336 Audible Warning Device: Testing and Inspection CHIME WARNING SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The hard-wired circuits between components related to the chime warning system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, procedures for proper wire and connector repair, details of wire harness routing and retention, connector pin-out information, and location views for the various wire harness connectors, splices, and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime warning system or the electronic controls or communication between modules and other devices that provide some features of the chime warning system. The most reliable, efficient, and accurate means to diagnose the chime warning system or the electronic controls and communication related to chime warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Cigarette Lighter: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Page 9340 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Page 9341 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 Cigarette Lighter: Connector Views Connector - (FRONT CONSOLE) 3 WAY LIGHTER-CIGAR - (FRONT CONSOLE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 Cigarette Lighter: Electrical Diagrams HORN/CIGAR LIGHTER/POWER OUTLET - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Horn/Cigar Lighter/Power Outlet 8W-41-01 Horn/Cigar Lighter/Power Outlet 8W-41-02 (EVIC) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Horn/Cigar Lighter/Power Outlet 8W-41-03 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 Horn/Cigar Lighter/Power Outlet 8W-41-04 (Except Export) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9366 Compass: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY MODULE-COMPASS - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9367 Compass: Description and Operation DESCRIPTION The Remote Compass Module (RCM) (2) is a separate stand alone module mounted to the top of the instrument panel (1). The RCM can be accessed by removing the defroster grille, See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. If the compass position sensor (Remote Compass Module) is inoperative and requires replacement, See: Service and Repair/Removal and Replacement/Compass Module - Removal for the appropriate procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 9368 Compass: Testing and Inspection REMOTE COMPASS MODULE The Remote Compass Module (RCM) data is transferred on the Controller Area Network (CAN) Data Bus circuit. The RCM and Electronic Vehicle Information Center (EVIC) will not function properly if the bus messages are not properly received. If no EVIC data is displayed, check the CAN Data Bus circuit communications, the RCM, the Instrument Cluster functions and the Totally Integrated Power Module (TIPM). Any diagnosis of the RCM and EVIC display should begin with the use of a scan tool and the appropriate diagnostic service information. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration Compass: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. NOTE: Calibration is required anytime a new RCM is installed. Upon installation of the new RCM the "CAL" message will appear in the Electronic Vehicle Information Center (EVIC) display. The RCM will automatically calibrate if the vehicle is driven in two or more circles, slowly, and away from large metal objects. The RCM can also be calibrated by performing the following procedure. NOTE: Confirmation that the proper variance zone is programmed, is recommended whenever manual compass calibration is performed. See: Driver/Vehicle Information Display/Adjustments for the appropriate procedure. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (4) several times until "Calibrate Compass (Yes)" is displayed. 4. Momentarily depress and release the RESET push button (3) to initiate the calibration procedure. The "CAL" symbol will come on solid in the EVIC display. 5. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" symbol will disappear from the display to indicate successful compass calibration. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration > Page 9371 Compass: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance will need to be updated to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration > Page 9372 2. Turn the ignition switch to the ON/RUN position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (4) until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. 4. Press and release the RESET push button (3) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. NOTE: The default for the compass variance from the factory is 8. During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. Press and release the Compass Temperature (C/T) push button (2) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures Compass: Procedures COMPASS DEMAGNETIZING DEGAUSSING TOOL #6029 A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel of the vehicle. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the vehicle. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass, See: Driver/Vehicle Information Display/Adjustments and adjust the compass variance, See: Driver/Vehicle Information Display/Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 9375 Compass: Removal and Replacement Compass Module - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal 3. Remove the retaining screw (3) securing the Remote Compass Module (RCM) (2) to the instrument panel (1). 4. Disconnect the RCM electrical connector (4). 5. Remove the RCM from the vehicle. Compass Module - Installation INSTALLATION 1. Position the Remote Compass Module (RCM) (2) onto the top of the Instrument Panel (IP) (1). 2. Connect the electrical connector (4). 3. Install the RCM retaining screws (3). 4. Install the defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille Installation 5. Connect the battery negative cable. 6. Perform the Compass Variance Adjustment, See: Driver/Vehicle Information Display/Adjustments. 7. Perform the Manual Compass Calibration, See: Driver/Vehicle Information Display/Adjustments. 8. Verify proper compass operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9380 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9381 Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9382 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9385 Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Driver/Vehicle Information Display: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 9390 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Module-Totally Integrated Power (TIPM) - Provides Circuit Protection, Supplies Power and Controls Many Vehicle Electronic Components Module-Front Control (FCM) - Controls Vehicle Electronic Components Module-Integrated Power (IPM) - Provides Circuit Protection, Supplies Power and Controls Some Vehicle Electronic Components Fuse/Relay Block (FRB) - Provides Circuit Protection and Supplies Power To Vehicle Power Distribution Center (PDC) - Hard Wired Box Provides Circuit Protection and Supplies Power To Vehicles Junction Block (JB) - Provides Circuit Protection, Supplies Power and Provides Circuit Pass-Through Connectivity From Harness To Harness Circuit Functions CIRCUIT FUNCTIONS Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9407 Driver/Vehicle Information Display: Electrical Diagrams OVERHEAD CONSOLE - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9408 Overhead Console 8W-49-01 (Except Navigation) Overhead Console 8W-49-02 (Navigation) Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9409 Overhead Console 8W-49-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Description DESCRIPTION The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel (2) and engine temperature (1) gauges. The display in the lower right part of the instrument cluster (15) below the tachometer (13) shows the vehicle odometer related functions. These functions include Trip Odometer (ODO), Trip A and Trip B readouts. The instrument cluster pushbutton (21) can be used to scroll through the different odometer functions. See: Instrument Cluster / Carrier/Description and Operation/Instrument Cluster - Description for additional information on the instrument cluster and related functions. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display. It is located in the instrument cluster below the fuel and temperature gauges. Vehicles equipped with steering wheel-mounted buttons (described) are also equipped with the EVIC. The EVIC consists of the following: - System Status - Vehicle information warning message displays - Tire Pressure Monitor System (TPM) - If Equipped - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions The EVIC system is comprised of several different components. Those components are: - Instrument Cluster (sometimes referred to as Cab Compartment Node [CCN]) - ASBM EVIC Function Buttons - Ambient Temperature Sensor - Remote Compass Module (RCM) - Controller Area Network (CAN) Data Bus - Local Interface Network (LIN) Data Bus The EVIC display is part of the Instrument Cluster assembly and is not serviced as a separate component. If the display is inoperative the complete Instrument Cluster assembly must be replaced, See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 9412 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the "ON" position. When the ignition switch is turned to the "ON" position, the EVIC display will return to the last function being displayed before the ignition was turned to the "OFF" position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC function buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button allows the driver to select the Compass/Temperature, Trip Computer, Personal Settings or System Status functions. The STEP button is used to toggle through options or features of the Trip Computer, Personal Settings or System Status functions. Pressing and releasing the RESET button allows the selection of setting or resetting of the function currently displayed at that time. Pressing and releasing the C/T (compass/temperature) button will cause the EVIC to return to the compass/temperature display mode from any other mode. EVIC DISPLAY MODES SYSTEM STATUS MODE System display mode displays warnings and user interaction messages on the EVIC display. The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - Turn Signal On (with a continuous warning chime if the vehicle is driven more than 1 mile [1.6 km] with either turn signal on) - Left Front Turn Signal Lamp Out (with a single chime) - Left Rear Turn Signal Lamp Out (with a single chime) - Right Front Turn Signal Lamp Out (with a single chime) - Right Rear Turn Signal Lamp Out (with a single chime) - RKE (Remote Keyless Entry ) Battery Low (with a single chime) - Channel # Transmit. - Channel # Training. - Channel # Trained. - Clearing Channels. - Channels Cleared. - Did Not Train. - Left Front Low Pressure (with a single chime). - Left Rear Low Pressure (with a single chime). - Right Front Low Pressure (with a single chime). - Right Rear Low Pressure (with a single chime). - Check TPM System (with a single chime). - Low Fuel - Cal - Oil Change Required (with a single chime) - Low Washer Fluid - Coolant Low - Key in Ignition - Lights On PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. Pressing and releasing the STEP button will scroll through the following personal settings choices: - Language When in this display you may select one of three languages for all display nomenclature, including the trip functions and the navigation system (if equipped). Press the RESET button while in this display to select English, Espanol, or Francais. Then, as you continue, the information will display in the selected language. NOTE: The EVIC will not change the UConnect(TM) language selection. - Unlock Doors Automatically on Exit When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Remote Key Unlock When DRIVER DOOR 1ST PRESS is selected, only the driver's door will unlock on the first press of the remote keyless Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 9413 entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. When ALL DOORS 1ST PRESS is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "Driver Door 1st Press" or "All Doors 1st Press" appears. - Sound Horn with Remote Key Lock When ON is selected, a short horn sound will occur when the remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Flash Lights with Remote Key Lock When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Delay Turning Headlights Off When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears. - Headlights On with Wipers (Available with Auto Headlights Only) When this feature is selected and the headlight switch is in the AUTO position, the headlights will activate approximately 10 seconds after the wipers are turned on. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Delay Power Off to Accessories Until Exit When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped), power sunroof (if equipped), and power outlets will remain active for up to 10 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," or "10 min." appears. Confirmation of Voice Commands - If Equipped When ON is selected, all voice commands from the UConnect(TM) system are confirmed. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - Display Units of Measure in The EVIC, odometer, and navigation system (if equipped) can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears. COMPASS/TEMPERATURE Compass heading and outside temperature are displayed on the EVIC display screen. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and one of 15 compass variance settings can be programmed. Outside temperature is displayed in °C (degrees Celsius) or °F (degrees Fahrenheit). For additional information regarding the compass, refer to Personal Settings (Customer Programmable Features). TRIP COMPUTER Press and release the MENU button until one of the following Trip Functions displays in the EVIC: - Average Fuel Economy - Distance To Empty - Elapsed Time - Display Units of Measure in Press the STEP button to cycle through all the Trip Computer functions. The Trip Functions mode displays the following information: - Average Fuel Economy Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. - Distance To Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. DTE cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. - Elapsed Time Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. - Display Units of Measure in: To make your selection, press and release the RESET button until "US" or "METRIC" appears. To Reset The Display Reset will only occur while a resettable function is being displayed. Press and release the RESET button once to clear the resettable function being displayed. To reset all resettable functions, press and release the RESET button a second time within 3 seconds of resetting the currently displayed function (>Reset ALL will display during this 3 second window). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9414 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not receive. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN and LIN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). Should the RCM become disconnected, the instrument cluster display will go blank. The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the Instrument Cluster, the RCM, the CAN Data Bus and the LIN Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration Driver/Vehicle Information Display: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDAs, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. NOTE: Calibration is required anytime a new RCM is installed. Upon installation of the new RCM the "CAL" message will appear in the Electronic Vehicle Information Center (EVIC) display. The RCM will automatically calibrate if the vehicle is driven in two or more circles, slowly, and away from large metal objects. The RCM can also be calibrated by performing the following procedure. NOTE: Confirmation that the proper variance zone is programmed, is recommended whenever manual compass calibration is performed. See: for the appropriate procedure. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (4) several times until "Calibrate Compass (Yes)" is displayed. 4. Momentarily depress and release the RESET push button (3) to initiate the calibration procedure. The "CAL" symbol will come on solid in the EVIC display. 5. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" symbol will disappear from the display to indicate successful compass calibration. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 9417 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance will need to be updated to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 9418 2. Turn the ignition switch to the ON/RUN position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (4) until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. 4. Press and release the RESET push button (3) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. NOTE: The default for the compass variance from the factory is 8. During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. Press and release the Compass Temperature (C/T) push button (2) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING DEGAUSSING TOOL #6029 A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel of the vehicle. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the vehicle. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass, See: Adjustments and adjust the compass variance, See: Adjustments. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 9421 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry the switch and bezel assembly (3) away from the steering wheel at the inner retaining tab (1) and the outer bezel edge (2). 4. With the switch and bezel assembly free from the steering wheel, lift the assembly up and disconnect the switch electrical connector. 5. Using trim stick (special tool # C-4755) or equivalent, gently pry the switch bezel retainers (2) away from the switch tabs (1), while applying pressure to the back side of the switch. Remove the switch from the bezel. Electronic Vehicle Information Center Switch - Installation INSTALLATION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 9422 1. Position the steering wheel switch onto the switch bezel aligning the switch tabs (1) with the bezel retainers (2). 2. Press the switch into the bezel, until the switch is held in place by all four retainers. 3. Position the switch and bezel assembly (3) over the steering wheel and connect the switch electrical connector. 4. Align the switch bezel tab (1) with the slot in the steering wheel and press the switch and bezel assembly (3) into the steering wheel until it is secured in place. 5. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation. 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Restraints System Verification Test. 7. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9423 Driver/Vehicle Information Display: Tools and Equipment SPECIAL TOOLS DE GAUSER - 6029 RF Detector - 9001 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 9428 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 9429 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 9430 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 9433 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 9436 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 9437 Fuel Gauge Sender: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9440 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9441 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9442 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9443 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9444 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9445 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9446 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9447 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9448 Fuel Gauge Sender: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Pump Module - Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9449 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9450 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Pump Module - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation Technical Service Bulletin # J09 Date: 090325 Recall - Power Inverter Connector Relocation March 2009 Dealer Service Instructions for: Safety Recall J09 Power Inverter Connector Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles NOT equipped with a 115 volt power inverter (sales code JKV) built through February 6, 2009 (MDH 020614). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The power inverter 9-way white electrical connector on about 16,800 of the above vehicles may become contaminated, potentially causing the connector to melt and/or catch fire. Repair The power inverter 9-way white electrical connector must be relocated and the 25 amp fuse for the 9-way white connector must be removed from the Totally Integrated Power Module (TIPM). Parts Information Special Tools No special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 9460 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Move the driver's seat to the full forward position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 9461 2. Working from the left rear door opening, locate the seat wiring harness where it comes through the slit in the carpet under the driver's seat (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 9462 3. Locate the taped back 9-way white connector under the carpet by accessing it through the carpet slit (Figure 2). 4. Break the tape and pull the 9-way white connector through the carpet opening toward the seat in-line connectors (Figure 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 9463 5. Using a plastic tie strap, permanently tie back the white 9-way connector approximately 2 inches (50 mm) from the back of the seat inline grey connector. CAUTION: Assure that the 9-way white connector cannot lay on the carpet. 6. Move the seat back to its original position. 7. Open the hood. 8. Locate the Totally Integrated Power Module (TIPM) in the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 9464 9. Open the cover on the TIPM and locate, remove and discard the 25 amp fuse shown in Figure 4. 10. Close the cover on the TIPM. 11. Close the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > J09 > Mar > 09 > Recall Power Inverter Connector Relocation > Page 9465 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > Recalls for DC/AC Inverter: > NHTSA09V082000 > Mar > 09 > Recall 09V082000: Power Inverter Connector DC/AC Inverter: Recalls Recall 09V082000: Power Inverter Connector VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: March 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V082000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 16852 SUMMARY: Chrysler is recalling 16,852 M/Y 2009 Dodge Journey equipped without optional 115 volt auxiliary power outlet. An unused electrical connector for the optional 115 volt auxiliary power outlet option may become corroded and could short circuit. CONSEQUENCE: If the fuse for this circuit does not blow, the connector could overheat and potentially catch fire. REMEDY: Dealers will re-route and stow the 115 volt auxiliary power outlet connector and pull the 25 amp fuse to remove power from this unused circuit free of charge. The recall is expected to begin during March 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation Technical Service Bulletin # J09 Date: 090325 Recall - Power Inverter Connector Relocation March 2009 Dealer Service Instructions for: Safety Recall J09 Power Inverter Connector Models 2009 (JC) Dodge Journey NOTE: This recall applies only to the above vehicles NOT equipped with a 115 volt power inverter (sales code JKV) built through February 6, 2009 (MDH 020614). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The power inverter 9-way white electrical connector on about 16,800 of the above vehicles may become contaminated, potentially causing the connector to melt and/or catch fire. Repair The power inverter 9-way white electrical connector must be relocated and the 25 amp fuse for the 9-way white connector must be removed from the Totally Integrated Power Module (TIPM). Parts Information Special Tools No special tools are required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 9475 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Move the driver's seat to the full forward position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 9476 2. Working from the left rear door opening, locate the seat wiring harness where it comes through the slit in the carpet under the driver's seat (Figure 1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 9477 3. Locate the taped back 9-way white connector under the carpet by accessing it through the carpet slit (Figure 2). 4. Break the tape and pull the 9-way white connector through the carpet opening toward the seat in-line connectors (Figure 2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 9478 5. Using a plastic tie strap, permanently tie back the white 9-way connector approximately 2 inches (50 mm) from the back of the seat inline grey connector. CAUTION: Assure that the 9-way white connector cannot lay on the carpet. 6. Move the seat back to its original position. 7. Open the hood. 8. Locate the Totally Integrated Power Module (TIPM) in the engine compartment. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 9479 9. Open the cover on the TIPM and locate, remove and discard the 25 amp fuse shown in Figure 4. 10. Close the cover on the TIPM. 11. Close the hood. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > J09 > Mar > 09 > Recall - Power Inverter Connector Relocation > Page 9480 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > DC/AC Inverter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DC/AC Inverter: > NHTSA09V082000 > Mar > 09 > Recall 09V082000: Power Inverter Connector DC/AC Inverter: All Technical Service Bulletins Recall 09V082000: Power Inverter Connector VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Journey 2009 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: March 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V082000 NHTSA ACTION NUMBER: N/A COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 16852 SUMMARY: Chrysler is recalling 16,852 M/Y 2009 Dodge Journey equipped without optional 115 volt auxiliary power outlet. An unused electrical connector for the optional 115 volt auxiliary power outlet option may become corroded and could short circuit. CONSEQUENCE: If the fuse for this circuit does not blow, the connector could overheat and potentially catch fire. REMEDY: Dealers will re-route and stow the 115 volt auxiliary power outlet connector and pull the 25 amp fuse to remove power from this unused circuit free of charge. The recall is expected to begin during March 2009. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. J09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 9489 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > EVIC Equipped Vehicles Oil Change Reminder Lamp: Service and Repair EVIC Equipped Vehicles Oil Change Required Your vehicle is equipped with an engine oil change indicator system. The Oil Change Required message will flash in the EVIC for approximately 5 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON position. To turn off the message temporarily, press and release the MENU button on the instrument cluster. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: 1. Turn the ignition switch to the ON position (Do not start the engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair > EVIC Equipped Vehicles > Page 9492 Oil Change Reminder Lamp: Service and Repair Non-EVIC Equipped Vehicles Change Oil Message (Base and Mid Line Clusters) Your vehicle is equipped with an engine oil change indicator system. The CHANGE OIL message will flash in the instrument cluster odometer for approximately 12 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON position. To turn off the message temporarily, press and release the TRIP ODOMETER button on the instrument cluster. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: 1. Turn the ignition switch to the ON position (Do not start the engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9496 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9497 Oil Pressure Sender: Diagrams Connector (GAS) - (ENGINE) 2 WAY SWITCH-OIL PRESSURE (GAS) - (ENGINE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor (1) is a variable resistor located under the bottom right side of the front bumper reinforcement (2). The sensor is attached to the power steering line bracket with a pushpin style retainer and can be accessed through the right opening in the front fascia assembly. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor Description > Page 9503 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The applicable instrument cluster display then displays the proper ambient temperature. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 9504 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus, the Local Area Network (LIN) data bus and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (130° F), or if the sensor circuit is shorted, 60° C (130° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the instrument cluster may be necessary. See: Instrument Cluster / Carrier/Testing and Inspection/Component Tests and General Diagnostics for the appropriate procedure. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, further testing of the instrument cluster may be necessary. See: Instrument Cluster / Carrier/Testing and Inspection/Component Tests and General Diagnostics for the appropriate procedure. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the "ON" position for readings to meet test specifications. 1. Turn the ignition switch to the "OFF" position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the "ON" position. The display should now read - 40° C (- 40° F). If OK, go to 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the "OFF" position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the "ON" position. The display should now read 60° C (130° F). If OK, go to 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE: If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update. 5. Turn the ignition switch to the "OFF" position. Remove the jumper wire. Turn the ignition switch to the "ON" position and wait until the display again reads - 40° C (- 40° F). Turn the ignition switch to the "OFF" position. Reconnect the ambient temperature sensor. Turn the ignition switch to the "ON" position. The display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to 6 6. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the LIN data bus circuit, the TIPM and the ambient temperature sensor (refer to the SENSOR TEST). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Working through the opening in the right side of the front fascia, disconnect the wire harness connector from the ambient temperature sensor (1). 3. Remove the fastener that secures the ambient temperature sensor to the power steering line bracket. 4. Remove the ambient temperature sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal > Page 9507 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Working through the opening in the right side of the front fascia, position the ambient temperature sensor (1) in the vehicle. 2. Install the fastener that secures the ambient temperature sensor (1) to the power steering line bracket. 3. Connect the wire harness connector to the ambient temperature sensor. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9511 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9512 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a foot-operated or hand-operated park brake lever mechanism. FOOT-OPERATED Foot-Operated Park Brake Switch The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED Hand-Operated Park Brake Switch The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 9515 connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 9516 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Page 9517 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9520 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9521 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9522 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9528 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9529 Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9530 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9533 Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module Fuel Gauge Sender: Locations Fuel Pump Module Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 9538 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 9539 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module > Page 9540 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (Body) 4 Way Connector C1 - (BODY) 4 WAY MODULE-FUEL PUMP - (BODY) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module C1 (Body) 4 Way > Page 9543 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Fuel Tank Jumper) 2 Way Connector C2 (AWD) - (FUEL TANK JUMPER) 2 WAY MODULE-FUEL PUMP (AWD) - (FUEL TANK JUMPER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION FWD The front wheel drive (FWD) fuel pump module contains the electric fuel pump, fuel pump reservoir, fuel level sending unit, fuel pressure regulator, and fuel filter. The fuel level sending unit is serviceable See: Service and Repair/Removal. The fuel pump module, fuel pump reservoir, fuel pressure regulator, and fuel filter is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel pump modules. The AWD fuel pump modules contains the main fuel pump module (1), auxiliary fuel pump module (2), main fuel level sending unit, auxiliary fuel level sending unit, fuel pump reservoir, fuel pressure regulator and fuel filter. The main fuel level sending unit is located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module and is serviced as an assembly See: Service and Repair/Fuel Pump Module Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 9546 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION FWD The front wheel drive (FWD) fuel pump module is located inside the fuel tank with a fuel level sending unit and pressure regulator. The fuel pump module is a positive displacement, gerotor, driven by a 12 volt DC permanent magnet electric motor. The fuel pump module draws fuel through a internal filter and pushes it through the motor to an outlet pipe. The fuel pump module contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump pressure regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess fuel pressure in the fuel pump module to purge into the fuel tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The fuel pump pressure regulator adjusts fuel system pressure to approximately 400 ± 34 kPa (58 ± 5 psi). AWD Operation of the all wheel drive (AWD) main fuel pump module is similar to the FWD with the addition of a auxiliary fuel pump module with a auxiliary fuel level sending unit and draws fuel from the base of the auxiliary fuel pump module (2) through an internal tube. The auxiliary fuel pump module flow rate is greater than the vehicle fuel consumption rate so that the auxiliary side of the tank is emptied before fuel is depleted from the primary side. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 9547 Fuel Gauge Sender: Description and Operation Description DESCRIPTION FWD The front wheel drive (FWD) vehicles have a serviceable fuel level sending unit located on the fuel pump reservoir See: Service and Repair/Removal. AWD The all wheel drive (AWD) vehicles with the saddle fuel tank configurations have a main (1) and auxiliary (2) fuel level sending units. The main fuel level sending unit located on the main fuel pump reservoir (1) is serviceable See: Service and Repair/Removal. The auxiliary fuel level sending unit (2) is integrated with the auxiliary fuel pump module. The auxiliary fuel pump module and the fuel level sending unit is serviced as an assembly See: Service and Repair/Fuel Pump Module - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL MAIN FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 2. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 4. Rotate the breaker bar counterclockwise and remove the lock-ring. NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 5. Mark the main fuel pump module orientation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9550 WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. NOTE: Do not spill fuel into the interior of the vehicle. 6. Raise the main fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle. 7. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle. 8. If equipped with AWD, disconnect the internal fuel line from the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9551 9. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm. 10. Remove and discard the rubber O-ring seal. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9552 1. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal. NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly. 2. Mark the auxiliary fuel pump module orientation (1). NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. 3. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 4. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 5. Rotate the breaker bar counterclockwise and remove the lock-ring. 6. Raise the auxiliary fuel pump module and disconnect the internal fuel line. 7. Remove the auxiliary fuel pump module from the fuel tank using caution not to bend the float arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9553 8. Remove and discard the rubber O-ring seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9554 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION MAIN FUEL PUMP MODULE CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. If equipped with AWD, Connect the internal fuel line to the main fuel pump module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9555 3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly. 5. Position the lock-ring over top of the main fuel pump module. 6. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. AUXILIARY FUEL PUMP MODULE WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9556 CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal. 2. Connect the internal fuel line to the auxiliary fuel pump module. 3. Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm. NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly. 4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel gauge to work properly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9557 5. Position the lock-ring over top of the auxiliary fuel pump module. 6. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring. 7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318. 8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged. 9. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9558 Fuel Gauge Sender: Service and Repair Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury. 1. Remove the fuel pump module See: Fuel Pump Module - Removal. 2. Disconnect the fuel level sending unit electrical connector (1). CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not pull the fuel level sending unit by the wires or the float arm. 3. Using your finger, press the fuel level sending unit snap tab to the left while gently pushing up on the bottom of the fuel level sending unit and remove. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9559 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Do not touch the terminals or the resistor card. CAUTION: Do not handle the new fuel level sending unit by the float arm. 1. Position the new fuel level sending unit to the fuel pump module reservoir. 2. Gently push the fuel level sending unit down until the snap tab (2) engages. CAUTION: Ensure the fuel level sending unit wires are routed so they do not get pinched between the coils of the spring when the module is Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9560 completely compressed. 3. Connect the fuel level sending unit electrical connector. 4. Install the fuel pump module See: Fuel Pump Module - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor (1) is a variable resistor located under the bottom right side of the front bumper reinforcement (2). The sensor is attached to the power steering line bracket with a pushpin style retainer and can be accessed through the right opening in the front fascia assembly. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description > Page 9565 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster, sometimes referred to as the Cab Compartment Node (CCN), display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The applicable instrument cluster display then displays the proper ambient temperature. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 9566 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus, the Local Area Network (LIN) data bus and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (130° F), or if the sensor circuit is shorted, 60° C (130° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the instrument cluster may be necessary. See: Instrument Cluster / Carrier/Testing and Inspection/Component Tests and General Diagnostics for the appropriate procedure. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, further testing of the instrument cluster may be necessary. See: Instrument Cluster / Carrier/Testing and Inspection/Component Tests and General Diagnostics for the appropriate procedure. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the "ON" position for readings to meet test specifications. 1. Turn the ignition switch to the "OFF" position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the "ON" position. The display should now read - 40° C (- 40° F). If OK, go to 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the "OFF" position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the "ON" position. The display should now read 60° C (130° F). If OK, go to 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE: If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update. 5. Turn the ignition switch to the "OFF" position. Remove the jumper wire. Turn the ignition switch to the "ON" position and wait until the display again reads - 40° C (- 40° F). Turn the ignition switch to the "OFF" position. Reconnect the ambient temperature sensor. Turn the ignition switch to the "ON" position. The display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to 6 6. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the LIN data bus circuit, the TIPM and the ambient temperature sensor (refer to the SENSOR TEST). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Working through the opening in the right side of the front fascia, disconnect the wire harness connector from the ambient temperature sensor (1). 3. Remove the fastener that secures the ambient temperature sensor to the power steering line bracket. 4. Remove the ambient temperature sensor from the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor Removal > Page 9569 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Working through the opening in the right side of the front fascia, position the ambient temperature sensor (1) in the vehicle. 2. Install the fastener that secures the ambient temperature sensor (1) to the power steering line bracket. 3. Connect the wire harness connector to the ambient temperature sensor. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9573 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9574 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION There are two unique park brake switches used on this vehicle, depending upon whether the vehicle has a foot-operated or hand-operated park brake lever mechanism. FOOT-OPERATED Foot-Operated Park Brake Switch The foot-operated park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, outboard of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The foot-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. HAND-OPERATED Hand-Operated Park Brake Switch The hand-operated park brake switch (1) is located on the park brake lever mechanism on the floor panel transmission tunnel below the center floor console. This switch includes a spade-type output terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out and Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch Description > Page 9577 connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3) with an integral grounding lug on one end and an integral actuating lever and follower on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The hand-operated park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch Description > Page 9578 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION Both the foot-operated and hand-operated park brake switch are normally closed, mechanically actuated leaf contact switches that are operated by the foot or hand park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used as a logic input by the EMIC for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the park brake switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to park brake switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 9579 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the wire harness connector from the terminal of the park brake switch (2) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. HAND-OPERATED 1. Disconnect and isolate the battery negative cable. 2. Remove the console from the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9582 3. Pull the parking brake lever (1) upward to apply the parking brake. 4. Disconnect the wire harness connector from the terminal of the park brake switch (2) located on the right side of the park brake lever mechanism. 5. Remove the screw (3) that secures the switch to the park brake lever bracket. 6. Remove the switch from the park brake lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9583 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. FOOT-OPERATED 1. Reach under the left end of the instrument panel to position the park brake switch (2) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. HAND-OPERATED 1. Position park brake switch (2) onto the right side of the park brake lever (1) bracket. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever bracket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9584 2. Install and tighten the screw (3) that secures the switch to the lever bracket. Tighten the screw to 2.5 Nm (24 in. lbs.). 3. Reconnect the wire harness connector to the terminal of the switch. 4. Reinstall the console onto the floor panel transmission tunnel.See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 5. Reconnect the battery negative cable. 6. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the center floor console to access the gear selector unit. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Firmly grasp the socket (1) on the side of the gear selector housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the shifter housing. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Transmission Range Indicator Lamp - Removal > Page 9589 Shift Indicator: Service and Repair Transmission Range Indicator Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the socket (1) on the side of the gear selector housing. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening in the side of the gear selector housing. 4. Insert the bulb and socket into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the center floor console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Maintenance/Wheels and Tires/Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors (1) can be easily identified by the part number. CAUTION: Although additional sensors operating at 433 MHz sensors are available and are used in other applications, they are not interchangeable. Always make sure the correct sensor is being used and be sure to replace the sensor with the correct part number. NOTE: Once mounted inside a tire and wheel assembly you are not able to visually see the difference between this sensor and other 315 MHz and 433 MHz sensors. At that point, the TPM/RKE Analyzer 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body and part number. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 9596 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 9597 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. NOTE: The TPM-RKE Analyzer will not define the mode. The TPM sensor can be in one of the following operating modes: - OFF MODE - A new TPM sensor will be in this mode. In this mode the sensor does not transmit periodically on its own. By forcing a transmission from the sensor with the TPM-RKE Analyzer, it will change to the STATIONARY MODE. The sensor will also automatically change from OFF mode to the STATIONARY MODE once it experiences a great increase in pressure (i.e. installation into a wheel/tire assembly and then inflated). - WAL MODE - This is the operating mode the sensor assumes when the vehicle is driven over 15mph (24km/h), but only after the vehicle was previously parked for a duration of 18 minutes or greater. In WAL MODE the sensors transmit every 33 seconds and these transmissions contain left/right information that allows the TPM Module to determine sensor location on the vehicle. WAL MODE lasts for the first 10 minutes of consecutive driving, then NORMAL DRIVE mode ensues. - FACTORY MODE- This is a special case of WAL MODE. If a TPM sensor has just been taken out of OFF MODE, then for the first 3 minutes of the WAL period (10 minutes) the sensors transmit at an accelerated rate of every 10 seconds. After the first 20 drives, then the sensors never again transmit out of FACTORY MODE. - NORMAL MODE - This is the operating mode the sensor assumes after the first 10 minutes of a drive. In NORMAL MODE the sensors transmit every 66 seconds and cease transmitting left/right information. - SERVICE MODE- Once a vehicle stops, the sensors go into SERVICE MODE. After 18 minutes of no driving then the sensors go into the STATIONARY MODE. If the vehicle was stopped for less than 18 minutes and driving resumes, then the sensors go back to the NORMAL MODE. - STATIONARY MODE - When a vehicle has been stopped for more then 18 minutes, then the sensor is forced into STATIONARY MODE. In STATIONARY MODE the sensor never transmits any pressure information. The sensor leaves STATIONARY MODE and enters WAL MODE when the vehicle is driven above 15mph (24km/h). Each sensor's (transmitter) broadcast is uniquely coded so that the TPM module can monitor the state of each of the sensors on the four rotating road wheels. The TPM module can automatically learn and store the sensor's ID while driving "within 20 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The TPM module can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. See: Maintenance 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9600 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9601 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9602 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9603 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (applied to driver's side B-pillar). Make sure original style and color valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly (1) on vehicle See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the WIN with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Vehicle Theft Security Verification Tests/Tire Pressure Monitor (TPM) Verification Test. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Locations > Page 9607 Transmission Mode Indicator - A/T: Diagrams Connector - (BODY) 3 WAY LAMP-PRNDL - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > Backup Lamp Switch - Description Backup Lamp Switch: Description and Operation Backup Lamp Switch - Description DESCRIPTION Vehicles equipped with a manual transmission (2) have a normally open, spring-loaded plunger type backup lamp switch (1). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the left facing surface of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Refer to the service and diagnostic information for the manual transmission type installed in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > Backup Lamp Switch - Description > Page 9614 Backup Lamp Switch: Description and Operation Backup Lamp Switch - Operation OPERATION The backup lamp switch controls a path to ground for the Totally Integrated Power Module (TIPM) on the reverse switch signal circuit. The TIPM reads this input through an internal pull-up, then controls an output through a high side driver that regulates the flow of battery voltage to the backup lamp bulbs as appropriate on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives ground at all times through a take out and eyelet terminal of the wire harness that is secured to the body sheet metal. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the backup lamp switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to backup lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > Page 9615 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Locate and disconnect the engine wire harness connector from the backup lamp switch connector receptacle. 3. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 4. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations > Page 9620 Brake Lamp Relay: Diagrams Connector - (BODY) 5 WAY RELAY-BRAKE LAMP - (BODY) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal Brake Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Removal BULB Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP NOTE: The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate battery negative cable. 2. Remove the outer rear lamp unit. See: Service and Repair/Tail Stop Turn Lamp - Removal. 3. Firmly grasp the appropriate bulb socket (1 or 2 ) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. INNER LAMP NOTE: The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the inner rear lamp unit. See: Service and Repair/Tail Stop Turn Lamp - Removal. 3. Firmly grasp the appropriate bulb socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 9625 Brake Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Installation BULB Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate bulb socket (1 or 2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the outer rear lamp unit housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the outer rear lamp unit. See: Service and Repair/Tail Stop Turn Lamp - Installation. 7. Reconnect the battery negative cable. INNER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 9626 lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate bulb socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the inner rear lamp unit housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the inner rear lamp unit. See: Service and Repair/Tail Stop Turn Lamp - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch (Early Build) (Body) 6 Way Brake Light Switch: Diagrams Stop Lamp Switch (Early Build) (Body) 6 Way Connector (EARLY BUILD) - (BODY) 6 WAY SWITCH-STOP LAMP (EARLY BUILD) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch (Early Build) (Body) 6 Way > Page 9632 Brake Light Switch: Diagrams Stop Lamp Switch (Normal Build) (Body) 6 Way Connector (NORMAL BUILD) - (BODY) 6 WAY SWITCH-STOP LAMP (NORMAL BUILD) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and both are illustrated and described in the paragraphs that follow. EARLY PRODUCTION This brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket on the dash panel under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. This brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. LATE PRODUCTION This brake lamp switch (1) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (4) containing six terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (2) on one end of the switch housing. The plunger has a telescoping self-adjustment feature that is activated after the switch is installed by pulling the brake pedal upward to its normal at-rest position. The telescoping plunger can be pulled outward from the switch housing to repeat the self-adjustment procedure if necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 9635 This brake lamp switch cannot be repaired. If the switch is damaged or ineffective it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 9636 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION Both the early and late production brake lamp switches control three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the Center High Mounted Stop Lamp (CHMSL) and the Totally Integrated Power Module (TIPM) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake signal 1 circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Totally Integrated Power Module (TIPM) on an ignition run/start control output circuit, and supplies this battery voltage to the PCM on a brake signal 2 circuit only when the brake pedal is released (brake lamp switch plunger is depressed). The PCM sends electronic brake lamp switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus for use as an additional logic input for controlling many other vehicle functions and features. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication that provide some features related to brake lamp switch operation. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to brake lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 9637 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Early Production Late Production 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the Eary Production-type brake lamp switch from the mounting bracket. The self-adjusting plunger of this switch is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 9638 Brake Light Switch: Adjustments ADJUSTMENT - LATE PRODUCTION TYPE ONLY Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and, only the late production type switch can be readjusted following initial installation using this adjustment procedure. If the early production type switch requires readjustment for any reason, it must be replaced with a new switch. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Depress and hold the brake pedal in the depressed position. 4. Pull the brake lamp switch plunger all the way out of the switch housing to its fully extended position. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 5. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 6. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch - Description. EARLY PRODUCTION 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Locate the brake lamp switch (3) on the brake pedal support bracket (2) under the instrument panel. 4. Disconnect the wire harness connector (4) from the switch. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket (1). 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Discard the removed brake lamp switch. The brake lamp switch self-adjusting plunger is a one time only feature. If the switch is removed from the bracket, it MUST be replaced with a new switch. LATE PRODUCTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 9641 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Locate the brake lamp switch (2) on the brake pedal support bracket (4) under the instrument panel. 4. Depress and hold the brake pedal in the depressed position. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket. 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Release the brake pedal. 8. Disconnect the wire harness connector (1) from the switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 9642 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch - Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. EARLY PRODUCTION CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Obtain a new brake lamp switch. The adjustment lever on the new switch should be at about a 45 degree angle to the switch connector receptacle. If the adjustment lever is parallel with the connector receptacle, the switch adjustment has already been set and the switch must be scrapped. DO NOT ATTEMPT TO RESET OR READJUST THE BRAKE LAMP SWITCH. 2. Depress and hold the brake pedal in the depressed position. 3. Align the tabs on the brake lamp switch (2) locking collar with the keyed hole in the brake pedal support bracket (1) below the instrument panel. 4. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the brake pedal support bracket until the switch housing is firmly seated against the bracket. 5. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 9643 6. Release the brake pedal, but do not pull it upward. 7. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch MUST be installed. 8. Reconnect the wire harness connector (4) to the brake lamp switch (3). 9. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 10. Reconnect the battery negative cable. LATE PRODUCTION 1. Be certain that the brake lamp switch (2) plunger is pulled all the way out of the switch housing to its fully extended position. 2. Reconnect the wire harness connector (1) to the connector receptacle on the switch. 3. Depress and hold the brake pedal in the depressed position. 4. Align the tabs on the brake lamp switch locking collar with the keyed hole in the brake pedal support bracket (2). 5. Insert the tab on the brake lamp switch locking collar through the keyed hole in the support bracket until the switch housing is firmly seated against the bracket. 6. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the support bracket. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 7. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 8. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 9. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Bulb > Component Information > Service and Repair > Courtesy Lamp - Removal Cargo Lamp Bulb: Service and Repair Courtesy Lamp - Removal BULB 1. Disconnect and isolate the battery negative cable. 2. Using a thin flat-bladed tool, gently pry between one end of the lamp lens (1) and the lower liftgate trim panel to remove the lens from the liftgate lamp housing. 3. Carefully unsnap the bulb (2) from the two bulb holders within the lamp housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Bulb > Component Information > Service and Repair > Courtesy Lamp - Removal > Page 9649 Cargo Lamp Bulb: Service and Repair Courtesy Lamp - Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the ends of the bulb (2) with the two bulb holders within the liftgate lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Align the lamp lens (1) with the lamp housing, then use firm and even hand pressure to snap the lens onto the housing. 4. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Page 9653 Center Mounted Brake Lamp: Diagrams Connector - (LIFTGATE) 2 WAY LAMP-CENTER HIGH MOUNTED STOP - (LIFTGATE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center Mounted Brake Lamp - Removal Center Mounted Brake Lamp: Service and Repair Center Mounted Brake Lamp - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws (4) that secure the Center High Mounted Stop Lamp (CHMSL) (3) to the liftgate header panel (1). 3. Pull the CHMSL away from the liftgate far enough to access and disconnect the connector (2) of the liftgate wire harness (1) from the connector receptacle on the back of the lamp. 4. Remove the CHMSL from the liftgate. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center Mounted Brake Lamp - Removal > Page 9656 Center Mounted Brake Lamp: Service and Repair Center Mounted Brake Lamp - Installation INSTALLATION 1. Check to be certain that the two U-nuts in the Center High Mounted Stop Lamp (CHMSL) opening of the liftgate header panel are properly installed and in good condition. 2. Position the CHMSL (3) near the opening in the liftgate header panel. 3. Reconnect the connector (2) of the liftgate wire harness (1) to the connector receptacle on the back of the lamp. 4. Position the CHMSL into the liftgate header opening. 5. Install and tighten the two screws (4) that secure the CHMSL to the liftgate header panel. Tighten the screws to 1.5 Nm (15 in. lbs.). 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 9661 Glove Box Lamp: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY LAMP-GLOVE BOX - (INSTRUMENT PANEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp Bulb - Removal Glove Box Lamp: Service and Repair Glove Box Lamp Bulb - Removal BULB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through and behind the upper outboard corner of instrument panel glove box opening to access the bulb (2) on the side of the glove box lamp and switch unit (1). 4. Pull the base of the bulb straight out of the bulb holder. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp Bulb - Removal > Page 9664 Glove Box Lamp: Service and Repair Glove Box Lamp/Switch - Removal LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through and behind the upper outboard corner of instrument panel glove box opening to access and depress the retaining latch on either side of the glove box lamp and switch unit (1). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp Bulb - Removal > Page 9665 Glove Box Lamp: Service and Repair Glove Box Lamp Bulb - Installation BULB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Reach through and behind the upper outboard corner of instrument panel glove box opening to align the base of the bulb (2) with the bulb holder on the side of the glove box lamp and switch unit (1). 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Close the glove box door. 4. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp Bulb - Removal > Page 9666 Glove Box Lamp: Service and Repair Glove Box Lamp/Switch - Installation LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the glove box lamp and switch unit (1) to the instrument panel glove box opening. 2. Reconnect the wire harness connector to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9671 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9672 Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9673 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9676 Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome/Reading Lamp Bulb - Removal Dome Lamp Bulb: Service and Repair Dome/Reading Lamp Bulb - Removal Dual Lamp BULB - DUAL LAMP 1. Disconnect and isolate the battery negative cable. 2. Remove the dual dome/reading lamp (2) from the headliner. See: Service and Repair/Dome/Reading Lamp - Removal. 3. With the lamp lens (1) in the open position, carefully unsnap the bulb (3) from the two bulb holders within the lamp housing. Overhead Console BULB - OVERHEAD CONSOLE 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Grasp the dome/reading lamp socket (3) firmly and push it to one side far enough to unsnap the socket latch features from the lamp housing (4). 4. Pull the socket and bulb (2) out of the lamp housing. 5. Pull the base of the bulb straight out of the lamp socket. Single Lamp BULB - SINGLE LAMP Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome/Reading Lamp Bulb - Removal > Page 9682 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch (1) on one side of the dome lamp bezel between the lens and the lamp housing. 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (2). 5. Carefully unsnap the bulb from the two bulb holders within the dome lamp housing. Light Emitting Diode Unit LIGHT EMITTING DIODE UNIT NOTE: Each Light Emitting Diode (LED) dome/reading lamp contains two articulating eyeball-type LED pod units with integral lens-actuated switches and printed circuit boards that are available for separate service replacement. The rear LED dome/reading lamp also has a fixed auxiliary LED and printed circuit board unit which is also available for separate service replacement. ARTICULATED EYEBALL POD UNIT 1. Disconnect and isolate the battery negative cable. 2. Remove the LED dome/reading lamp unit. See: Service and Repair/Dome/Reading Lamp - Removal. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the pod (1) upward far enough to disengage the pivot pin on one side of the pod from the pivot socket of the pod receptacle. 4. Lift the pod out of its receptacle within the dome/reading lamp housing. 5. On rear LED dome/reading lamp units only, from the top of the lamp housing, disconnect the pod pigtail wire connector from the fixed auxiliary LED lamp printed circuit board in the center of the lamp. FIXED AUXILIARY LED AND CIRCUIT BOARD UNIT Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome/Reading Lamp Bulb - Removal > Page 9683 1. Disconnect and isolate the battery negative cable. 2. Remove the rear LED dome/reading lamp unit. See: Service and Repair/Dome/Reading Lamp - Removal. 3. Remove and disconnect the two articulated eyeball LED pods (1) from the lamp housing. 4. Disconnect the lamp wiring from the auxiliary LED wiring connector (3). 5. Remove the six screws (2) that secure the printed circuit board to the lamp housing. 6. Remove the auxiliary LED and circuit board unit from the lamp housing (4). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome/Reading Lamp Bulb - Removal > Page 9684 Dome Lamp Bulb: Service and Repair Dome/Reading Lamp Bulb - Installation Dual Lamp BULB - DUAL LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. With the dome/reading lamp lens (1) in the open position, align the ends of the bulb (3) with the two bulb holders within the lamp housing (2). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Reinstall the lamp into the headliner. See: Service and Repair/Dome/Reading Lamp - Installation. 4. Reconnect the battery negative cable. Overhead Console BULB - OVERHEAD CONSOLE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb (2) with the overhead console dome/reading lamp socket (3). 2. Push the bulb straight into the socket until the base is fully seated. 3. Align the socket and bulb with the keyed opening in the lamp housing (4). 4. Insert the bulb and socket straight into the hosing until the socket latch features are both fully engaged. 5. Reinstall the overhead console (1) to the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome/Reading Lamp Bulb - Removal > Page 9685 Single Lamp BULB - SINGLE LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the ends of the bulb (2) with the two bulb holders within the dome lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the housing. 4. Reconnect the battery negative cable. Light Emitting Diode Unit LIGHT EMITTING DIODE UNIT NOTE: Each Light Emitting Diode (LED) dome/reading lamp contains two articulating eyeball-type LED pod units with integral lens-actuated switches and printed circuit boards that are available for separate service replacement. The rear LED dome/reading lamp also has a fixed auxiliary LED and printed circuit board unit which is also available for separate service replacement. ARTICULATED EYEBALL POD UNIT 1. On rear LED dome/reading lamp units only, from the top of the lamp housing, reconnect the pod pigtail wire connector to the fixed auxiliary LED lamp printed circuit board in the center of the lamp. 2. Align the LED lamp pod (1) with the receptacle within the dome/reading lamp housing. 3. Engage the pivot pin on one side of the pod with the pivot socket on one side of the pod receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the receptacle outward far enough to engage the pivot pin on the other side of the pod with the other pivot socket. 5. Using a trim stick or equivalent, flex the housing at point (1) and install lamp pod. 6. Reinstall the LED dome/reading lamp unit. See: Service and Repair/Dome/Reading Lamp - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome/Reading Lamp Bulb - Removal > Page 9686 7. Reconnect the battery negative cable. FIXED AUXILIARY LED AND CIRCUIT BOARD UNIT 1. Position the auxiliary LED and circuit board unit (4) into the lamp housing. 2. Install and tighten the six screws (2) that secure the printed circuit board to the lamp housing. Tighten the screws securely. 3. Reconnect the lamp wiring to the auxiliary LED wiring connector (3). 4. Reinstall and reconnect (1) the two articulated eyeball LED pods into the lamp housing. 5. Reinstall the rear LED dome/reading lamp unit. See: Service and Repair/Dome/Reading Lamp - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Diagrams > Flashlight Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Diagrams > Flashlight > Page 9692 Flashlight: Diagrams Flashlight (Body) 3 Way Connector - (BODY) 3 WAY LAMP-FLASHLIGHT - (BODY) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Description and Operation > Rechargeable Flashlight - Description Flashlight: Description and Operation Rechargeable Flashlight - Description DESCRIPTION An optional removable and rechargeable flashlight (3) is encased within a molded plastic housing, which is secured within a bezel/charging station (2) at the back of the left quarter inner trim panel (1) by two tabs on the end opposite the clear flashlight lens and a push-push type latch mechanism. The flashlight is powered by a rechargeable and replaceable lithium battery. A momentary switch on the flashlight electronic circuit board is actuated by a plastic push button located on the side of the flashlight housing. When the flashlight is turned ON it illuminates two clear Light Emitting Diode (LED) units to create a wide and bright light beam. A red LED unit on the side of the flashlight housing behind the push button illuminates as the battery becomes discharged to indicate that the unit requires recharging. The bezel/charging station unit, the flashlight battery and the flashlight unit are each available for separate service replacement. If any other component of the flashlight or bezel/charging station are damaged or ineffective, the complete flashlight unit or bezel/charging station unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Description and Operation > Rechargeable Flashlight - Description > Page 9695 Flashlight: Description and Operation Rechargeable Flashlight - Operation OPERATION The rechargeable lithium battery within the flashlight automatically recharges while the flashlight is nested in its receptacle within the bezel charging station and the engine is running. The flashlight has a pair of electrical contacts that mate with contacts within the charging station that provide a source of recharging current. The red Light Emitting Diode (LED) unit on the side of the flashlight behind the ON-OFF push button illuminates when the charge of the flashlight battery is becoming depleted. The flashlight is removed from the bezel/charging station by pushing it momentarily at the depression marked PUSH on the flashlight housing, then releasing it and swinging it downward far enough to disengage two slots on the lower end of the flashlight from two tabs within the charging station. When the flashlight is removed from its receptacle in the bezel/charging station, it can be used as an auxiliary light source in emergencies or other situations where a portable light source is required. The flashlight is turned ON or OFF by momentarily depressing and releasing the ON-OFF push button on the side of the flashlight housing. Reverse the removal procedure to restore the flashlight to the bezel/charging station and to recharge the flashlight battery. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Service and Repair > Procedures Flashlight: Procedures FLASHLIGHT BATTERY REPLACEMENT 1. Insert a small screwdriver or another suitable tool into each of the two notches (2) between the upper (1) and lower (3) case halves of the flashlight and use a twisting action to separate the case. 2. Remove the lower case (4) from the upper case (3) and set it aside. 3. Lightly lift the latch tab (2) at the back of the upper case and slide the battery (1) rearward far enough to remove it from the case. 4. Install the new battery by sliding it between the latch tab and the case until it is engaged by the latch tab. The battery must be installed with the positive (+) terminal oriented toward the upper case (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Flashlight > Component Information > Service and Repair > Procedures > Page 9698 Flashlight: Removal and Replacement Rechargeable Flashlight Bezel/Charging Station - Removal BEZEL/CHARGING STATION 1. Disconnect and isolate the battery negative cable. 2. Pull the rear of the left quarter trim panel (2) away from the D-pillar far enough to access the back of the bezel/charging station (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the body wire harness connector (4) from the connector receptacle on the back of the bezel/charging station. 4. Compress the spring clip retainers (3) far enough to allow the bezel/charging station to be pushed out of the mounting hole through the face of the quarter trim panel. Six spring clip retainers are used, three on the forward side and three on the rearward side of the unit. 5. Remove the bezel/charging station from the vehicle. Rechargeable Flashlight Bezel/Charging Station - Installation BEZEL/CHARGING STATION 1. Align the bezel/charging station (1) with the mounting hole near the rear of the left quarter trim panel (2). 2. Using hand pressure, push the bezel/charging station into the mounting hole firmly and evenly until all 6 of the spring clip retainers (3) snap into place on the back side of the trim panel. 3. Reconnect the body wire harness connector (4) to the connector receptacle on the back of the bezel/charging station. 4. Reinstall the left quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb - Removal Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb - Removal BULB CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower inner front wheel house splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 3. Disconnect the headlamp and dash wire harness connector from the front fog lamp bulb (2) connector receptacle (1). 4. Firmly grasp the bulb on the back of the front fog lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the bulb straight out from the keyed opening in the housing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb - Removal > Page 9704 Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb - Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the front fog lamp bulb (2) with the keyed opening on the back of the front fog lamp housing. 2. Insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. The bulb connector receptacle should be pointed outboard and horizontal in orientation. 4. Reconnect the headlamp and dash wire harness connector to the front fog lamp bulb connector receptacle (1). 5. Reinstall the lower inner front wheel house splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9709 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9710 Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9711 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9714 Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description Hazard Warning Switch: Description and Operation Hazard Warning Switch - Description DESCRIPTION The hazard switch (3) is integral to the instrument panel switch pod (1), which is secured to the instrument panel center bezel just above the heater and air conditioner controls. A red, stencil-like International Control and Display Symbol icon for Hazard Warning identifies the hazard switch button. The remainder of the hazard switch circuitry is concealed within the instrument panel switch pod. The hazard switch button has panel lamps dimmer controlled illumination for night visibility. The switch button latches to a slightly lowered position when the hazard warning system is activated and the icon on the switch button will illuminate at an increased intensity while the turn signals and turn signal indicators are flashing. The switch button unlatches to a position flush with the other push buttons in the switch pod when the hazard warning is deactivated. All of the circuitry and components of the hazard switch are contained within a molded black plastic instrument panel switch pod housing. A single connector receptacle is integral to the back of the switch pod housing. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The hazard switch cannot be adjusted or repaired and, if ineffective or damaged, the entire instrument panel switch pod unit must be replaced. See: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description > Page 9720 Hazard Warning Switch: Description and Operation Hazard Warning Switch - Operation OPERATION The status of the hazard switch is continually monitored by the circuitry within the instrument panel switch pod. The switch pod receives battery voltage at all times on a fused battery feed circuit, and a path to ground at all times through the instrument panel wire harness. The only other inputs to the switch pod consists of electronic communication with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the single wire Local Interface Network (LIN) data bus. Whenever the hazard switch is in its unlatched and raised position, the hazard warning system is selected and the switch pod circuitry provides a hard wired output to the Totally Integrated Power Module (TIPM). When the TIPM receives a hazard switch input it then controls hazard warning system operation and flash rate by controlling battery voltage outputs through high side drivers on the right and left, front and rear turn signal feed circuits. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hard wired circuits for the instrument panel switch pod may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the hazard warning switch or the electronic controls and communication between other modules and devices that provide some features of the hazard warning system. The most reliable, efficient, and accurate means to diagnose the hazard switch or the electronic controls and communication related to hazard warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair BULBS HEADLAMP HIGH BEAM CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the headlamp bulb and base (5) with the keyed opening on the back of the front lamp unit reflector. 2. Insert the bulb into the reflector until the base is firmly seated. 3. Rotate the bulb base clockwise about 30 degrees to lock it into place. 4. Reconnect the wire harness connector to the connector receptacle integral to the headlamp bulb base. 5. Reconnect the battery negative cable. HEADLAMP LOW BEAM CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the headlamp bulb and base (2) with the keyed opening on the back of the front lamp unit reflector. 2. Insert the bulb into the reflector until the base is firmly seated. 3. Rotate the bulb base clockwise about 30 degrees to lock it into place. 4. Reconnect the wire harness connector to the connector receptacle integral to the headlamp bulb base. 5. Reconnect the battery negative cable. POSITION LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The following procedure applies only to vehicles manufactured for certain export markets. Vehicles manufactured for domestic markets do not have a position lamp bulb, socket or wiring provided in the front lamp unit. 1. Align the base of the bulb with the position lamp bulb socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the front lamp unit housing. 4. Insert the socket and bulb straight into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the wire harness connector to the connector receptacle integral to the position lamp bulb socket. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 9725 TURN SIGNAL/SIDE MARKER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the park/turn signal lamp bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the front lamp unit housing. 4. Insert the socket and bulb straight into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the wire harness connector to the connector receptacle integral to the park/turn signal lamp bulb socket. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Headlamp Dimmer Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 9731 Headlamp Dimmer Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9734 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9735 Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9736 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9739 Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Headlamp Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 9745 Headlamp Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9748 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9749 Headlamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9750 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9753 Headlamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 9758 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal Horn Switch: Service and Repair Horn Switch - Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal > Page 9761 Horn Switch: Service and Repair Horn Switch - Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > License Plate Lamp Bulb - Removal License Plate Bulb: Service and Repair License Plate Lamp Bulb - Removal BULB 1. Disconnect and isolate the battery negative cable. 2. Remove the license plate lamp from the underside of the liftgate handle and light bar assembly. See: Service and Repair/License Plate Lamp Removal. 3. Pull the base of the bulb straight out of the license plate lamp bulb socket (1). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > License Plate Lamp Bulb - Removal > Page 9767 License Plate Bulb: Service and Repair License Plate Lamp Bulb - Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the license plate lamp bulb with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the top of the license plate lamp housing. 4. Insert the bulb and socket into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the lamp into the mounting hole on the underside of the liftgate handle and light bar assembly. See: Service and Repair/License Plate Lamp - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9772 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9773 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9774 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9775 Parking Lamp: Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9776 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9777 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9778 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9779 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9780 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Left Front Lamp Assembly > Page 9781 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way Parking Lamp: Diagrams Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way Connector C1 (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-LEFT FRONT (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9784 Parking Lamp: Diagrams Left Front Lamp Assembly C2 (Front End Module) 2 Way Connector C2 - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-LEFT FRONT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9785 Parking Lamp: Diagrams Left Front Lamp Assembly C3 (Front End Module) 3 Way Connector C3 - (FRONT END MODULE) 3 WAY LAMP-ASSEMBLY-LEFT FRONT - (FRONT END MODULE) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9786 Parking Lamp: Diagrams Left Front Lamp Assembly C4 (Except Export) (Front End Module) 2 Way Connector C4 (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-LEFT FRONT (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9787 Parking Lamp: Diagrams Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way Connector C1 (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-LEFT FRONT (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY Left Front Lamp Assembly C2 (Front End Module) 2 Way Connector C2 - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-LEFT FRONT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9788 Left Front Lamp Assembly C3 (Front End Module) 3 Way Connector C3 - (FRONT END MODULE) 3 WAY LAMP-ASSEMBLY-LEFT FRONT - (FRONT END MODULE) 3 WAY Left Front Lamp Assembly C4 (Except Export) (Front End Module) 2 Way Connector C4 (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-LEFT FRONT (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9789 Right Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way Connector C1 (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-RIGHT FRONT (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY Right Front Lamp Assembly C2 (Front End Module) 2 Way Connector C2 - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-RIGHT FRONT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9790 Right Front Lamp Assembly C3 (Front End Module) 3 Way Connector C3 - (FRONT END MODULE) 3 WAY LAMP-ASSEMBLY-RIGHT FRONT - (FRONT END MODULE) 3 WAY Right Front Lamp Assembly C4 (Except Export) (Front End Module) 2 Way Connector C4 (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY LAMP-ASSEMBLY-RIGHT FRONT (EXCEPT EXPORT) - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Lamp Assembly C1 (Except Export) (Front End Module) 2 Way > Page 9791 Left Tail Lamp Assembly C2 (Body/Trailer Tow) 3 Way Connector C2 - (BODY/TRAILER TOW) 3 WAY LAMP-ASSEMBLY TAIL-LEFT - (BODY/TRAILER TOW) 3 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Page 9796 Brake Lamp Relay: Diagrams Connector - (BODY) 5 WAY RELAY-BRAKE LAMP - (BODY) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Backup Lamp Switch - Description Backup Lamp Switch: Description and Operation Backup Lamp Switch - Description DESCRIPTION Vehicles equipped with a manual transmission (2) have a normally open, spring-loaded plunger type backup lamp switch (1). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the left facing surface of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Refer to the service and diagnostic information for the manual transmission type installed in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Backup Lamp Switch - Description > Page 9802 Backup Lamp Switch: Description and Operation Backup Lamp Switch - Operation OPERATION The backup lamp switch controls a path to ground for the Totally Integrated Power Module (TIPM) on the reverse switch signal circuit. The TIPM reads this input through an internal pull-up, then controls an output through a high side driver that regulates the flow of battery voltage to the backup lamp bulbs as appropriate on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives ground at all times through a take out and eyelet terminal of the wire harness that is secured to the body sheet metal. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication between other modules and devices that rely upon inputs from the backup lamp switch. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to backup lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Page 9803 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Locate and disconnect the engine wire harness connector from the backup lamp switch connector receptacle. 3. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 4. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch (Early Build) (Body) 6 Way Brake Light Switch: Diagrams Stop Lamp Switch (Early Build) (Body) 6 Way Connector (EARLY BUILD) - (BODY) 6 WAY SWITCH-STOP LAMP (EARLY BUILD) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Stop Lamp Switch (Early Build) (Body) 6 Way > Page 9809 Brake Light Switch: Diagrams Stop Lamp Switch (Normal Build) (Body) 6 Way Connector (NORMAL BUILD) - (BODY) 6 WAY SWITCH-STOP LAMP (NORMAL BUILD) - (BODY) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and both are illustrated and described in the paragraphs that follow. EARLY PRODUCTION This brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket on the dash panel under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. This brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. LATE PRODUCTION This brake lamp switch (1) is a three circuit, spring-loaded plunger actuated switch that is secured to the brake pedal support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (4) containing six terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the body wire harness. The switch plunger (3) extends through a mounting collar (2) on one end of the switch housing. The plunger has a telescoping self-adjustment feature that is activated after the switch is installed by pulling the brake pedal upward to its normal at-rest position. The telescoping plunger can be pulled outward from the switch housing to repeat the self-adjustment procedure if necessary. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 9812 This brake lamp switch cannot be repaired. If the switch is damaged or ineffective it must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 9813 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION Both the early and late production brake lamp switches control three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the Center High Mounted Stop Lamp (CHMSL) and the Totally Integrated Power Module (TIPM) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake signal 1 circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Totally Integrated Power Module (TIPM) on an ignition run/start control output circuit, and supplies this battery voltage to the PCM on a brake signal 2 circuit only when the brake pedal is released (brake lamp switch plunger is depressed). The PCM sends electronic brake lamp switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus for use as an additional logic input for controlling many other vehicle functions and features. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls and communication that provide some features related to brake lamp switch operation. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to brake lamp switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 9814 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Early Production Late Production 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the Eary Production-type brake lamp switch from the mounting bracket. The self-adjusting plunger of this switch is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 9815 Brake Light Switch: Adjustments ADJUSTMENT - LATE PRODUCTION TYPE ONLY Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable and, only the late production type switch can be readjusted following initial installation using this adjustment procedure. If the early production type switch requires readjustment for any reason, it must be replaced with a new switch. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Depress and hold the brake pedal in the depressed position. 4. Pull the brake lamp switch plunger all the way out of the switch housing to its fully extended position. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 5. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 6. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch - Description. EARLY PRODUCTION 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Locate the brake lamp switch (3) on the brake pedal support bracket (2) under the instrument panel. 4. Disconnect the wire harness connector (4) from the switch. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket (1). 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Discard the removed brake lamp switch. The brake lamp switch self-adjusting plunger is a one time only feature. If the switch is removed from the bracket, it MUST be replaced with a new switch. LATE PRODUCTION Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 9818 1. Disconnect and isolate the battery negative cable. 2. If equipped, remove the silencer pad from below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Removal. 3. Locate the brake lamp switch (2) on the brake pedal support bracket (4) under the instrument panel. 4. Depress and hold the brake pedal in the depressed position. 5. Rotate the brake lamp switch housing (2) counterclockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the brake pedal support bracket. 6. Pull the switch straight rearward from the keyed hole to remove it from the bracket. 7. Release the brake pedal. 8. Disconnect the wire harness connector (1) from the switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 9819 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION Two unique brake lamp switches are used in this vehicle, depending upon whether the vehicle was built during early or late production. These switches are not interchangeable. Both switches are illustrated and described elsewhere in this service information to assist in positive identification. See: Description and Operation/Stop Lamp Switch - Description. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. EARLY PRODUCTION CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Obtain a new brake lamp switch. The adjustment lever on the new switch should be at about a 45 degree angle to the switch connector receptacle. If the adjustment lever is parallel with the connector receptacle, the switch adjustment has already been set and the switch must be scrapped. DO NOT ATTEMPT TO RESET OR READJUST THE BRAKE LAMP SWITCH. 2. Depress and hold the brake pedal in the depressed position. 3. Align the tabs on the brake lamp switch (2) locking collar with the keyed hole in the brake pedal support bracket (1) below the instrument panel. 4. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the brake pedal support bracket until the switch housing is firmly seated against the bracket. 5. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 9820 6. Release the brake pedal, but do not pull it upward. 7. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch MUST be installed. 8. Reconnect the wire harness connector (4) to the brake lamp switch (3). 9. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 10. Reconnect the battery negative cable. LATE PRODUCTION 1. Be certain that the brake lamp switch (2) plunger is pulled all the way out of the switch housing to its fully extended position. 2. Reconnect the wire harness connector (1) to the connector receptacle on the switch. 3. Depress and hold the brake pedal in the depressed position. 4. Align the tabs on the brake lamp switch locking collar with the keyed hole in the brake pedal support bracket (2). 5. Insert the tab on the brake lamp switch locking collar through the keyed hole in the support bracket until the switch housing is firmly seated against the bracket. 6. Rotate the switch housing clockwise about 30 degrees to engage the tabs on the locking collar with the support bracket. CAUTION: Brake booster damage may occur if the brake pedal pull exceeds about 9 kilograms (20 pounds). 7. Release the brake pedal. Then pull the pedal lightly upward to its normal at-rest position. The pedal will set the plunger to the correct position as the pedal pushes the plunger into the switch housing. The switch plunger will make a light audible ratcheting noise as it self-adjusts. 8. If equipped, reinstall the silencer pad below the steering column. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Lower Silencer Panel - Installation. 9. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Combination Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 9826 Combination Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Combination Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9829 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9830 Combination Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9831 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Combination Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9834 Combination Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9839 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9840 Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9841 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9844 Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description Hazard Warning Switch: Description and Operation Hazard Warning Switch - Description DESCRIPTION The hazard switch (3) is integral to the instrument panel switch pod (1), which is secured to the instrument panel center bezel just above the heater and air conditioner controls. A red, stencil-like International Control and Display Symbol icon for Hazard Warning identifies the hazard switch button. The remainder of the hazard switch circuitry is concealed within the instrument panel switch pod. The hazard switch button has panel lamps dimmer controlled illumination for night visibility. The switch button latches to a slightly lowered position when the hazard warning system is activated and the icon on the switch button will illuminate at an increased intensity while the turn signals and turn signal indicators are flashing. The switch button unlatches to a position flush with the other push buttons in the switch pod when the hazard warning is deactivated. All of the circuitry and components of the hazard switch are contained within a molded black plastic instrument panel switch pod housing. A single connector receptacle is integral to the back of the switch pod housing. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The hazard switch cannot be adjusted or repaired and, if ineffective or damaged, the entire instrument panel switch pod unit must be replaced. See: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description > Page 9849 Hazard Warning Switch: Description and Operation Hazard Warning Switch - Operation OPERATION The status of the hazard switch is continually monitored by the circuitry within the instrument panel switch pod. The switch pod receives battery voltage at all times on a fused battery feed circuit, and a path to ground at all times through the instrument panel wire harness. The only other inputs to the switch pod consists of electronic communication with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the single wire Local Interface Network (LIN) data bus. Whenever the hazard switch is in its unlatched and raised position, the hazard warning system is selected and the switch pod circuitry provides a hard wired output to the Totally Integrated Power Module (TIPM). When the TIPM receives a hazard switch input it then controls hazard warning system operation and flash rate by controlling battery voltage outputs through high side drivers on the right and left, front and rear turn signal feed circuits. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hard wired circuits for the instrument panel switch pod may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the hazard warning switch or the electronic controls and communication between other modules and devices that provide some features of the hazard warning system. The most reliable, efficient, and accurate means to diagnose the hazard switch or the electronic controls and communication related to hazard warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Headlamp Dimmer Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 9855 Headlamp Dimmer Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9858 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9859 Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9860 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9863 Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Headlamp Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 9869 Headlamp Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9872 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9873 Headlamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9874 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9877 Headlamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 9881 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal Horn Switch: Service and Repair Horn Switch - Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Removal. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal > Page 9884 Horn Switch: Service and Repair Horn Switch - Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Driver Air Bag - Installation 5. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal Tail Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Removal BULB Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP NOTE: The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate battery negative cable. 2. Remove the outer rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Removal. 3. Firmly grasp the appropriate bulb socket (1 or 2 ) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. INNER LAMP NOTE: The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the inner rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Removal. 3. Firmly grasp the appropriate bulb socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 9890 Tail Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Installation BULB Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate bulb socket (1 or 2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the outer rear lamp unit housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the outer rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp Installation. 7. Reconnect the battery negative cable. INNER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 9891 lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate bulb socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the inner rear lamp unit housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the inner rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way Combination Switch: Diagrams Left Multifunction Switch C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION-LEFT - (INSTRUMENT PANEL) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Left Multifunction Switch C1 (Instrument Panel) 4 Way > Page 9898 Combination Switch: Diagrams Left Multifunction Switch C2 (Steering Wheel Jumper) 7 Way Connector C2 - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-LEFT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Combination Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are internally connected directly to the SCM. A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and connects the right multi-function switch (6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the back of the switch housing connects the SCM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Automatic Headlamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional automatic headlamps. - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9901 beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain export markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door or the liftgate is opened. - Interior Lamps On - The left multi-function switch control ring provides detent switching to illuminate all interior courtesy lamps simultaneously. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9902 Combination Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch receives clean grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the exterior lighting system. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is in the ON position, and OFF when the ignition switch is in the OFF position. The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Automatic Headlamps - The optional automatic headlamps feature is requested when the left multi-function switch control knob is rotated to the automatic (AUTO) detent position with the ignition switch in the ON position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp ON position is also selected, and will automatically move the control knob to the front fog lamps OFF position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function switch control stalk is pushed forward to the high beam selection detent position. The low beams are selected when the control stalk is pulled rearward to the low beam selection detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the low beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic beam select switch status message over the LIN data bus to the EMIC, which relays an electronic beam select switch request message over the CAN data bus to other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON position is also selected, and will automatically move the control knob to the rear fog lamp OFF position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends through an opening in the side of the clockspring case toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the cancel Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 9903 actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. - Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE mode is requested when the left multi-function switch control sleeve is rotated to the PARADE mode detent position. The SCM reads the resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting switch status message over the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Combination Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the left multi-function switch. 4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket integral to the left side of the clockspring (3) on the steering column. 5. Slide the switch (2) away from the clockspring (1) far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 6. Disconnect the jumper wire harness connector (3) from the connector receptacle on the inboard end of the left multi-function switch. 7. Remove the switch from the clockspring. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 9906 Combination Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the left multi-function switch (2) close enough to the mounting bracket (1) integral to the left side of the clockspring to reconnect the jumper wire harness connector (3) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the front of the left multi-function switch (1) to the mounting bracket (3) on the clockspring. Tighten the screw to 1 Nm (10 in. lbs.). 4. Reconnect the instrument panel wiring harness connector to the back of the left multi-function switch. 5. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation > Turn Signal Cancel Cam - Description Turn Signal Cancel Cam: Description and Operation Turn Signal Cancel Cam - Description DESCRIPTION The turn signal cancel cam is concealed within the clockspring case on the steering column. The turn signal cancel cam consists of integral eccentrics on the outer circumference of the molded plastic clockspring rotor. The clockspring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, Electronic Vehicle Information Center (EVIC) switches and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring is secured to the steering column and remains stationary. The rotor of the clockspring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If ineffective or damaged, the entire clockspring unit must be replaced. See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation > Turn Signal Cancel Cam - Description > Page 9911 Turn Signal Cancel Cam: Description and Operation Turn Signal Cancel Cam - Operation OPERATION When the left multi-function switch control stalk is moved to a latched turn signal ON position, a turn signal cancel actuator is extended from the inside surface of the switch housing through a small rectangular opening on the left side of the clockspring case toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the cam eccentrics will contact the actuator, automatically cancelling the turn signal event and releasing the latched left multi-function switch control stalk to the neutral or OFF position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal Turn Signal Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Removal BULB Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP NOTE: The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate battery negative cable. 2. Remove the outer rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Removal. 3. Firmly grasp the appropriate bulb socket (1 or 2 ) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. INNER LAMP NOTE: The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the inner rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Removal. 3. Firmly grasp the appropriate bulb socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out of the lamp. 5. Pull the base of the bulb straight out of the socket. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 9917 Turn Signal Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Installation BULB Each rear lamp unit for this vehicle consists of two pieces. An outer rear lamp unit that is secured at the rear of each quarter panel includes bulbs for the park (or tail) lamps, the brake (or stop) lamps and the turn signal lamps. An inner rear lamp is secured on each outboard side of the liftgate outer panel adjacent to the outer lamp and also includes a bulb for the park (or tail) lamps as well as a bulb for the backup (or reverse) lamps. OUTER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The outer rear lamp unit contains two bulbs. They are the tail/stop/rear side marker (1) and the turn signal (2). The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate bulb socket (1 or 2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the outer rear lamp unit housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the outer rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp Installation. 7. Reconnect the battery negative cable. INNER LAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The inner rear lamp unit contains two bulbs. The upper socket contains the tail lamp bulb, while the lower socket contains the backup Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 9918 lamp bulb. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate bulb socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the inner rear lamp unit housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the inner rear lamp unit. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Left Vanity Lamp Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Left Vanity Lamp > Page 9923 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left Vanity Lamp (Except Base) (Headliner) 2 Way Vanity Lamp: Diagrams Left Vanity Lamp (Except Base) (Headliner) 2 Way Connector (EXCEPT BASE) - (HEADLINER) 2 WAY LAMP-VANITY-LEFT (EXCEPT BASE) - (HEADLINER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left Vanity Lamp (Except Base) (Headliner) 2 Way > Page 9926 Vanity Lamp: Diagrams Right Vanity Lamp (Except Base) (Headliner) 2 Way Connector (EXCEPT BASE) - (HEADLINER) 2 WAY LAMP-VANITY-RIGHT (EXCEPT BASE) - (HEADLINER) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Vanity Lamp - Removal Vanity Lamp: Service and Repair Vanity Lamp - Removal REMOVAL NOTE: Vehicles equipped with optional vanity lamps have a lamp on each side of a covered mirror that is integral to each sun visor. Both lamps are controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for both of these lamps. 1. Disconnect and isolate the battery negative cable. 2. Open the lighted vanity mirror cover. 3. Using a small flat-bladed screwdriver, gently pry between the lamp lens (2) and housing (1) far enough to disengage the two tabs (1) at the outboard side of the lens from the lamp housing. 4. Carefully unsnap the bulb (3) from the two bulb holders within the lamp housing. 5. Remove the bulb from the lamp. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Vanity Lamp - Removal > Page 9929 Vanity Lamp: Service and Repair Vanity Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: Vehicles equipped with optional vanity lamps have a lamp on each side of a covered mirror that is integral to each sun visor. Both lamps are controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for both of these lamps. 1. Align the ends of the bulb (3) with the two bulb holders within the vanity lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Engage the tabs on the inboard edge of the lens (2) within the lamp housing. 4. Using hand pressure, press the outboard edge of the lens over the lamp housing until the two tabs (1) at the outboard edge of the lens snap into place. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9935 Heated Glass Element Relay: Diagrams Connector - (IN TIPM) 5 WAY RELAY-REAR WINDOW DEFOGGER - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION NOTE: Manual tri-zone temperature A/C-heater control shown. Other A/C-heater controls similar. The momentary push-button switch (1) for the rear window defogger (EBL) system is located in the A/C-heater control (2) in the center of the instrument panel. An amber indicator (3) will illuminate to indicate when the EBL system is turned on. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 9940 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9945 Heated Glass Element Relay: Diagrams Connector - (IN TIPM) 5 WAY RELAY-REAR WINDOW DEFOGGER - (IN TIPM) 5 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION NOTE: Manual tri-zone temperature A/C-heater control shown. Other A/C-heater controls similar. The momentary push-button switch (1) for the rear window defogger (EBL) system is located in the A/C-heater control (2) in the center of the instrument panel. An amber indicator (3) will illuminate to indicate when the EBL system is turned on. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 9951 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control Removal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 9956 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 9957 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 9958 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way Power Window Switch: Diagrams Left Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9961 Power Window Switch: Diagrams Right Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9962 Power Window Switch: Diagrams Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9963 Power Window Switch: Diagrams Driver Window/Door Lock Switch C2 (Front Door) 10 Way Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9964 Power Window Switch: Diagrams Left Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (REAR DOOR) 6 WAY Right Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9965 SWITCH-POWER WINDOW-RIGHT REAR - (REAR DOOR) 6 WAY Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Driver Window/Door Lock Switch C2 (Front Door) 10 Way Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9966 Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Passenger Window/Door Lock Switch (Except Base) (Front Door) 10 Way Connector (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9967 SWITCH-WINDOW/DOOR LOCK-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Passenger Window/Door Lock Switch (Base) (Front Door) 8 Way Connector (BASE) - (FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (BASE) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9968 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 9969 Power Window Switch: Testing and Inspection DIAGNOSIS AND TESTING For switch testing, remove the switch. See: Service and Repair/Power Window Switch - Removal. Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. MASTER WINDOW SWITCH TEST PASSENGER WINDOW SWITCH TEST Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL SWITCH - FRONT DOOR 1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. SWITCH - REAR DOOR 1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect the electrical connector. 4. Remove the switch from the handle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 9972 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION SWITCH - FRONT DOOR 1. Install the switch by snapping into place. 2. Connect switch wire connector. 3. Install the switch to the door trim panel. 4. Connect the battery negative cable. SWITCH - REAR DOOR 1. Connect the electrical connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Testing and Inspection Front Door Window Motor: Testing and Inspection WINDOW MOTOR 1. Remove door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 2. Connect positive (+) lead from a test battery to either of the two motor terminals. 3. Connect negative (-) lead from test battery to remaining motor terminal. 4. The motor should now rotate in one direction to either move window up or down. a. If window happens to already be in full UP position and motor is connected so as to move it in UP direction no movement will be observed. b. Likewise, motor connected to move window in DOWN direction no movement will be observed if window is already in full DOWN position. c. Reverse battery leads in 1 and 2 and window should now move. If window does not move, replace motor. 5. If window moved completely up or down, the test leads should be reversed one more time to complete a full window travel inspection. 6. If window does not move, check to make sure that it is free. 7. It is necessary that the window be free to slide up and down in the glass channels. If the window is not free to move up and down, the window lift motor will not be able to move the glass. 8. To determine if the glass is free, disconnect the regulator from the glass lift plate. Remove the two attaching screws, and slide the window up and down by hand. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal Front Door Window Motor: Service and Repair Window Regulator Motor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Disconnect the electrical connector. 4. Remove the mounting fasteners and remove the motor. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal > Page 9980 Front Door Window Motor: Service and Repair Window Regulator Motor - Installation INSTALLATION 1. Install the window motor and install the mounting fasteners. 2. Connect the electrical connector. 3. Install the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 9985 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 9986 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 9987 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way Power Window Switch: Diagrams Left Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9990 Power Window Switch: Diagrams Right Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9991 Power Window Switch: Diagrams Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9992 Power Window Switch: Diagrams Driver Window/Door Lock Switch C2 (Front Door) 10 Way Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9993 Power Window Switch: Diagrams Left Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (REAR DOOR) 6 WAY Right Rear Power Window Switch (Rear Door) 6 Way Connector - (REAR DOOR) 6 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9994 SWITCH-POWER WINDOW-RIGHT REAR - (REAR DOOR) 6 WAY Driver Window/Door Lock Switch C1 (Front Door) 14 Way Connector C1 - (FRONT DOOR) 14 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 14 WAY Driver Window/Door Lock Switch C2 (Front Door) 10 Way Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9995 Connector C2 - (FRONT DOOR) 10 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (FRONT DOOR) 10 WAY Passenger Window/Door Lock Switch (Except Base) (Front Door) 10 Way Connector (EXCEPT BASE) - (FRONT DOOR) 10 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9996 SWITCH-WINDOW/DOOR LOCK-PASSENGER (EXCEPT BASE) - (FRONT DOOR) 10 WAY Passenger Window/Door Lock Switch (Base) (Front Door) 8 Way Connector (BASE) - (FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER (BASE) - (FRONT DOOR) 8 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Rear Door) 6 Way > Page 9997 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 9998 Power Window Switch: Testing and Inspection DIAGNOSIS AND TESTING For switch testing, remove the switch. See: Service and Repair/Power Window Switch - Removal. Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. MASTER WINDOW SWITCH TEST PASSENGER WINDOW SWITCH TEST Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL SWITCH - FRONT DOOR 1. Disconnect and isolate the battery negative remote cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect switch wire connector. 4. Remove switch assembly. SWITCH - REAR DOOR 1. Disconnect and isolate the battery negative cable. 2. Using a trim tool, or equivalent, carefully pry up on the window switch until it disengages from the door trim panel. 3. Disconnect the electrical connector. 4. Remove the switch from the handle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 10001 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION SWITCH - FRONT DOOR 1. Install the switch by snapping into place. 2. Connect switch wire connector. 3. Install the switch to the door trim panel. 4. Connect the battery negative cable. SWITCH - REAR DOOR 1. Connect the electrical connector. 2. Install the switch to the door trim panel. 3. Connect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal Front Door Window Glass: Service and Repair Front Door Glass - Removal REMOVAL 1. Remove door trim panel and re-install the window switches, if equipped. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal 2. Remove the interior window trim molding. 3. Remove the door speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Removal 4. Drill a hole large enough to get a small puch through into the carrier plate (3). 5. Lower glass to approximately mid position and line up the glass lift plates (1) with the holes (2 and 3). 6. Using a punch or equivalent, press tabs releasing glass from window regulator (2 and 3). 7. Remove glass from channel. 8. Raise glass (1) upward and out of the opening at top of door. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal > Page 10007 Front Door Window Glass: Service and Repair Front Door Glass - Installation INSTALLATION 1. Lower glass (1) down and in the opening at top of door. 2. Slide glass downward making sure the glass holes properly lock into snaps (1). 3. Install the interior window trim molding. 4. Install the door speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Installation 5. Install door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal Liftgate Window Glass: Service and Repair Liftgate Glass - Removal REMOVAL NOTE: Windshield removal shown, backlite similar. 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windshield/Service Precautions 2. Remove liftgate trim panels. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 3. Remove rear window wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 4. Disconnect the heated backlite electrical connectors, if equipped. 5. Using a windshield cut-out wire or other suitable tool, separate the adhesive. 6. Carefully remove backlite. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10012 Liftgate Window Glass: Service and Repair Liftgate Glass - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The backlite fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the liftgate opening. Glass Preparation - Installing A Previously Installed Backlite 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windshield/Service Precautions 2. Level old bead of backlite adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. 3. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 4. Install the lower spacers (2) to the backlite approximately 25 mm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10013 5. Position backlite in center of liftgate opening and resting on the side and lower spacers. 6. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 7. Verify the backlite gap is parallel to with the liftgate opening. 8. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 9. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 10. Using a flash light, verify that glass primer is without damage. 11. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10014 12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 13. Allow primer to air dry for at least 10 minutes. 14. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Backlite 1. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 2. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. 3. Position backlite in center of liftgate opening and resting on the side and lower spacers. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10015 4. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 5. Verify the backlite gap is parallel to with the liftgate opening. 6. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 7. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 8. Apply primer to gluing surface at backlite seal. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10016 9. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 10. Allow primer to air dry for at least 10 minutes. 11. Using a flash light, verify that glass primer is without damage. Liftgate Opening Preparation NOTE: Windshield opening shown, liftgate opening similar. 1. Clean and vacuum liftgate opening. 2. Level old bead of liftgate opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10017 NOTE: Windshield opening shown, liftgate opening similar. 3. Clean and dry area of liftgate opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 5. Allow primer to air dry for at least 10 minutes. Backlite Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the backlite seal starting at bottom in center of the backlite. CAUTION: Always apply bead of adhesive to the backlite. Always install the backlite within 5 minutes after applying adhesive. 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Glass - Removal > Page 10018 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift backlite into place in the center of the liftgate opening and use the tape as a guide to aid installation of the backlite into the center of the cutout. 5. Carefully lay down the backlite and press on. CAUTION: It is no longer possible to move the backlite after installation. The backlite should never be pressed into place by more than one person, because the backlite can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install the rear wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 7. Install the liftgate trim panels. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal Quarter Window Glass: Service and Repair Quarter Glass - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions See: Windshield/Service Precautions. 2. Remove quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. NOTE: Windshield removal shown, quarter glass similar. 3. Using a windshield cut-out wire (4) or other suitable tool, separate the adhesive (2). 4. Release the tabs and the tabs on the alignment pin and carefully remove the quarter glass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10023 Quarter Window Glass: Service and Repair Quarter Glass - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing quarter glass to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The quarter glass fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Glass Preparation - Installing A Previously Installed Quarter Glass 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windshield/Service Precautions 2. Level old bead of quarter glass adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. NOTE: Typical primer installation shown. 3. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 4. Using a flash light, verify that glass primer is without damage. 5. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 6. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10024 NOTE: Make sure the primer does not touch the locating pins and tabs. 7. Allow primer to air dry for at least 10 minutes. 8. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Quarter Glass NOTE: Typical primer installation shown. 1. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 2. Apply primer to gluing surface at quarter glass seal. 3. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (3). NOTE: Make sure the primer does not touch the locating pins and tabs (2, 4). 4. Allow primer to air dry for at least 10 minutes. 5. Using a flash light, verify that glass primer is without damage. Quarter Glass Opening Preparation NOTE: Windshield opening shown, quarter glass opening similar. 1. Clean and vacuum quarter glass opening. 2. Level old bead of quarter glass opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10025 NOTE: Windshield opening shown, quarter glass opening similar. 3. Clean and dry area of quarter glass opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. NOTE: Make sure the primer does not touch the locating pins and tabs. 5. Allow primer to air dry for at least 10 minutes. Quarter Glass Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the quarter glass seal starting at bottom in center of the quarter glass. CAUTION: Always apply bead of adhesive to the quarter glass. Always install the quarter glass within 5 minutes after applying adhesive. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10026 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2). 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift quarter glass into place in the center of the quarter glass opening and install over the alignment tabs and pin. 5. Carefully lay down the quarter glass and press on. CAUTION: It is no longer possible to move the quarter glass after installation. The quarter glass should never be pressed into place by more than one person, because the quarter glass can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing quarter glass to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install quarter panel trim. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Outer Belt Molding - Removal Rear Door Window Glass Weatherstrip: Service and Repair Outer Belt Molding - Removal REMOVAL 1. Lower the window to the full down position. 2. Remove the rear door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove the front and rear mounting fasteners. 4. Remove the rear door belt molding (2) by carefully pulling up on the molding and remove from the rear door (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Outer Belt Molding - Removal > Page 10032 Rear Door Window Glass Weatherstrip: Service and Repair Outer Belt Molding - Installation INSTALLATION 1. Install the rear door belt molding (2) to the rear door (3). 2. Install the front and rear mounting fasteners. 3. Install the rear door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 4. Verify proper window operation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal Front Door Window Regulator: Service and Repair Front Door Window Regulator - Removal REMOVAL 1. Remove door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 2. Remove the door module assembly. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door Carrier Plate - Removal. 3. Remove the power window lift motor See: Power Window Motor/Front Door Window Motor/Service and Repair/Window Regulator Motor Removal. 4. Remove the regulator mounting fasteners. 5. Remove regulator from door module assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 10038 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Installation INSTALLATION 1. Position regulator on door module assembly and install mounting fasteners. 2. Install the power window motor. See: Power Window Motor/Front Door Window Motor/Service and Repair/Window Regulator Motor Installation. 3. Install the door module assembly. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door Carrier Plate Installation. 4. Install door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Removal REMOVAL 1. Remove door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 2. Remove the door module assembly. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove the power window lift motor. See: Power Window Motor/Front Door Window Motor/Service and Repair/Window Regulator Motor Removal 4. Remove the regulator mounting fasteners. 5. Remove regulator from door module assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 10043 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Installation INSTALLATION 1. Install regulator to door module assembly. 2. Install the regulator mounting fasteners. 3. Install the power window lift motor. See: Power Window Motor/Front Door Window Motor/Service and Repair/Window Regulator Motor Removal. 4. Install the door module assembly. See: Power Window Motor/Front Door Window Motor/Service and Repair/Window Regulator Motor Removal. 5. Install door trim panel. See: Power Window Motor/Front Door Window Motor/Service and Repair/Window Regulator Motor - Removal. 6. Verify Proper operation of the window. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. Chrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warrant will restore a vehicle to the requirements of FMVSS 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. Be sure to refer to the urethane manufacturer's directions for curing time specifications, and do not use adhesive after its expiration date. Vapors that are emitted from the urethane adhesive or primer could cause personal injury. Use them in a well-ventilated area. Skin contact with urethane adhesive should be avoided. Personal injury may result. Always wear eye and hand protection when working with glass. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10047 Windshield: Description and Operation DESCRIPTION The windshield is attached to the window frame (fence) with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the rubber seals are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and seals from the parts supplier. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal Windshield: Service and Repair Windshield - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions See: Service Precautions. 2. Remove the rear view mirror See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Removal. 3. Remove the cowl grille See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair CAUTION: Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield. 4. Using an assistant and a wire-type windshield cut-out tool (1, 3 and 4), cut and separate the urethane adhesive (2) securing the windshield to the windshield fence. 5. Carefully remove the windshield from the vehicle. 6. Remove molding from the sides of the windshield. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10050 Windshield: Service and Repair Windshield - Installation INSTALLATION WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly if the vehicle is in an accident. CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the windshield. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured. 1. If the windshield (1) is being reused, remove as much of the original urethane (3) as possible from the glass surface using a razor knife (2). CAUTION: To prevent corrosion, do not damage paint on windshield fence when removing original urethane. CAUTION: The windshield fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm (.039 in.) in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. CAUTION: Support spacers located near the cowl at the bottom of the windshield fence should be replaced with new spacers. Replace any missing or damaged spacers around the perimeter of the windshield fence. 2. Using a razor knife (2), level the original bead of urethane (1) on the windshield fence (3) to a thickness of approximately 1 mm (0.04 in.) and remove any damaged adhesive backed spacers. 3. Install new adhesive backed spacers along the windshield fence as required. 4. Install a new rubber seal along the sides of the windshield. 5. Using an assistant, position the windshield into the windshield opening and against the windshield fence and spacers. 6. Verify the windshield lays evenly against the fence at the top, bottom and sides of the opening. If not, the fence must be formed to the shape of the windshield. 7. Mark the windshield and the windshield fence with a grease pencil or pieces of masking tape to use as a reference for installation. 8. Using an assistant, remove the windshield from the windshield opening and place it on a suitable padded work surface. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10051 WARNING: Do not use solvent based glass cleaners to clean the windshield before applying glass prep and primer or poor glass adhesion may result. 9. Clean the inside of the windshield with an ammonia based glass cleaner and a lint-free cloth. 10. Apply glass prep adhesion promoter 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible. 11. Apply glass primer 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time. 12. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the windshield. 13. Re-prime any area that is not fully and evenly primed. 14. Clean the windshield fence with an ammonia based glass cleaner and a lint-free cloth. 15. Apply pinch weld primer 15 mm (0.75 in.) wide (1) around the windshield fence (2). Allow at least three minutes drying time. 16. Using a flashlight, verify that the primer is completely and evenly installed along the windshield fence. 17. Re-prime any area that is not fully and evenly primed. CAUTION: Always apply the bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying the adhesive. NOTE: If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10052 installing new adhesive. 18. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive (1) with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass (2) starting at the bottom center of the windshield. 19. Run the end of the adhesive bead (1) on the windshield (2) parallel to the start of the bead and smooth the ends flush. 20. Using an assistant, position the windshield over the windshield opening. 21. Using the grease pencil marks or tape as reference points, align the windshield to the windshield opening. 22. Carefully lower the windshield into the windshield opening. Guide the windshield and the rubber seals on the sides of the windshield into its proper location. CAUTION: It is not possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides. 23. Push the windshield inward until the windshield comes into contact with the spacers located on each side and the bottom of the windshield fence. 24. Install the cowl grill See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair. 25. Install the rear view mirror onto the windshield See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Washer Check Valve - Description Check Valve: Description and Operation Washer Check Valve - Description DESCRIPTION Diaphragm-type washer system check valves are standard equipment in this vehicle. The check valves for both the front and rear washer systems are integral to their respective washer nozzles. The check valve for the headlamp washer system, which is optional equipment only on vehicles manufactured for certain export markets, is integral to the headlamp washer hose tee fitting. The headlamp washer tee fitting is located behind the front fascia near the left headlamp washer nozzle. Each diaphragm-type check valve consists of a molded plastic valve body where a small diaphragm is held against the lip of an integral sump well by a small plastic piston and a coiled spring. The front and rear check valves cannot be adjusted or repaired and, if ineffective or damaged, the washer nozzle unit must replaced. The headlamp washer system tee fitting with the integral check valve also cannot be adjusted or repaired, and is serviced only as a unit with the headlamp washer hose assembly. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Washer Check Valve - Description > Page 10058 Check Valve: Description and Operation Washer Check Valve - Operation OPERATION Diaphragm-type washer system check valves provide more than one function. First, they prevent washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay from when the washer system is activated until washer fluid was dispensed through the washer nozzles because the washer pump would have to refill the washer plumbing from the reservoir to the nozzle. Such a drain-back condition could also result in water, dirt, or other outside contaminants being drawn into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning out through the washer nozzle after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing (5), the fluid pressure unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied to it by a piston (2) and coiled spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the washer nozzle (4). When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Hose > Component Information > Description and Operation > Headlamp Washer Hoses and Tubes - Description Headlamp Washer Hose: Description and Operation Headlamp Washer Hoses and Tubes Description HEADLAMP The headlamp washer system plumbing consists of a large diameter high pressure rubber hose (3) that is routed from the outlet nipple of the headlamp washer pump/motor unit on the washer reservoir to the barbed nipple of a tee fitting with an integral check valve located near the left headlamp washer nozzle on the back side of the front fascia (1). The other two barbed nipples of the tee fitting are connected to one short and one long length of hose that each terminate at a headlamp washer nozzle (2) behind the fascia and below the two front lamp units. The hose is secured and routed from left to right behind the fascia and above the fascia reinforcement by several routing clips. The hose connections at the nozzles and the washer pump are secured using molded plastic quick-connect fittings. The headlamp washer hose is serviced only as a complete unit. The molded plastic washer hose fittings and check valve cannot be repaired. If these fittings or the check valve are ineffective or damaged, the entire headlamp washer hose unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Hose > Component Information > Description and Operation > Headlamp Washer Hoses and Tubes - Description > Page 10063 Headlamp Washer Hose: Description and Operation Headlamp Washer Hoses and Tubes Operation HEADLAMP Washer fluid in the washer reservoir is pressurized and fed by the headlamp washer pump/motor unit through the headlamp washer system plumbing and fittings to the two headlamp washer nozzles. Whenever routing the washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Description and Operation > Headlamp Washer Relay - Description Headlamp Washer Motor Relay: Description and Operation Headlamp Washer Relay - Description DESCRIPTION The headlamp washer relay (1) is a conventional International Standards Organization (ISO) skirted relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns (2), and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The headlamp washer relay is located in a dedicated connector on a take out of the Front End Module (FEM) wire harness, and is secured to the radiator closure panel to the left of the washer reservoir in front of the Totally Integrated Power Module (TIPM) in the engine compartment, near the battery. The headlamp washer relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Description and Operation > Headlamp Washer Relay - Description > Page 10068 Headlamp Washer Motor Relay: Description and Operation Headlamp Washer Relay - Operation OPERATION The headlamp washer relay is an electromechanical switch that uses a low current input from the Totally Integrated Power Module (TIPM) to control a high current output to the headlamp washer pump/motor unit. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The headlamp washer relay terminals are connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The inputs and outputs of the headlamp washer relay include: - Common Feed Terminal - The common feed terminal (30) is connected to battery current on a fused B(+) circuit from a fuse in the Totally Integrated Power Module (TIPM) at all times. Coil Ground Terminal - The coil ground terminal (85) is connected to battery current on a fused run relay output circuit from a fuse in the TIPM at all times. This circuit is energized by the run relay only while the engine is running. - Coil Battery Terminal - The coil battery terminal (86) is connected to a low side driver output from the TIPM on a headlamp washer relay control circuit. The TIPM controls headlamp washer system operation through this relay connection. - Normally Open Terminal - The normally open terminal (87) is connected through a headlamp washer relay output circuit to the headlamp washer pump/motor unit at all times. When the relay is energized, the normally open terminal of the relay is connected to battery current from the fuse in the TIPM. - Normally Closed Terminal - The normally closed terminal (87A) is not connected to any circuit in this application, but will have battery current present whenever the headlamp washer relay coil is not energized. The headlamp washer relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or the communication between modules and other devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer relay or the electronic controls and communication related to headlamp washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Pump > Component Information > Description and Operation > Headlamp Windshield Washer Pump - Description Headlamp Washer Pump: Description and Operation Headlamp Windshield Washer Pump Description HEADLAMP The headlamp washer pump/motor unit (1) of vehicles so equipped is located on the top of a sump area just above and outboard of the reversible front and rear washer pump on the rearward facing side of the washer reservoir, on the upper left corner of the cooling module in the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. An inlet nipple (4) on the bottom of the pump housing (3) passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir. When the pump is installed in the reservoir the quick connect outlet nipple (5) on the pump housing points toward the left side of the vehicle and connects the unit to the headlamp washer hose. The headlamp washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by a light snap fit into a receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (2) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The headlamp washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire headlamp washer pump/motor unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Pump > Component Information > Description and Operation > Headlamp Windshield Washer Pump - Description > Page 10073 Headlamp Washer Pump: Description and Operation Headlamp Windshield Washer Pump Operation HEADLAMP Headlamp washer pump/motor unit operation is completely controlled by the Totally Integrated Power Module (TIPM) logic circuits based upon electronic wash request and lighting request message inputs received from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC monitors electronic washer switch and lighting switch status messages received over the Local Interface Network (LIN) data bus from the Steering Control Module (SCM). The SCM monitors analog and resistor multiplexed inputs from the front washer switch circuitry contained within the right (wiper) multi-function switch and the exterior lighting switch circuitry of the left (lighting) multi-function switch to determine the proper washer switch and lighting switch status messages to send. The headlamp washer relay control coil operates on battery voltage received from the run relay, so it is only functional while the engine is running. In addition, the TIPM will only allow the headlamp washers to operate when the headlamps are turned ON. The TIPM uses a low side driver to energize or de-energize the headlamp washer relay which, in turn, controls the operation of the headlamp washer pump/motor unit. The hard wired circuits and components of the headlamp washer pump/motor unit may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the headlamp washer pump/motor or the electronic controls or communication between other modules and devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer pump/motor unit or the electronic controls and communication related to headlamp washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Pump > Component Information > Service and Repair > Headlamp Windshield Washer Pump - Removal Headlamp Washer Pump: Service and Repair Headlamp Windshield Washer Pump - Removal HEADLAMP 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir into a clean container for reuse. 3. Remove the washer reservoir from the cooling module. See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir Removal. 4. Pull lightly outward on the top of the washer pump/motor housing (1), away from the washer reservoir to disengage the top of the motor from the receptacle in the reservoir. 5. Using hand pressure, firmly grasp and pull the washer pump upward far enough to disengage the pump inlet nipple from the rubber grommet seal/filter screen in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the rubber grommet seal/filter screen from the pump mounting hole in the washer reservoir and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Pump > Component Information > Service and Repair > Headlamp Windshield Washer Pump - Removal > Page 10076 Headlamp Washer Pump: Service and Repair Headlamp Windshield Washer Pump - Installation HEADLAMP 1. Install a new rubber grommet seal/filter screen into the headlamp washer pump/motor unit mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the inlet nipple of the headlamp washer pump/motor unit (1) to the rubber grommet seal/filter screen in the reservoir. 3. Using hand pressure, press firmly and evenly downward on the washer pump/motor unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump mounting hole of the reservoir. 4. Align the top of the washer pump/motor unit housing with the receptacle in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the motor housing snaps into the receptacle. 6. Reinstall the washer reservoir onto the cooling module. See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir Installation. 7. Refill the washer reservoir with the washer fluid drained during removal. 8. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Spray Nozzle > Component Information > Description and Operation > Headlamp Washer Nozzle - Description Headlamp Washer Spray Nozzle: Description and Operation Headlamp Washer Nozzle Description HEADLAMP Vehicles equipped with the optional headlamp washer system have two fixed headlamp washer nozzles (1), one secured to the front fascia beneath each front lamp unit. Each nozzle includes two orifices (1) to ensure complete headlamp lens coverage by the fluid streams emitted from the nozzle. The fixed body of the molded plastic nozzle is located below the front fascia. An integral mounting bezel (2) is secured by two integral latch features (3) within the mounting hole in the front fascia. A large diameter high pressure washer fluid supply hose from the dedicated headlamp washer pump/motor unit is routed to the nozzle, where it is secured by a quick connect fitting to the nipple fitting (4) at the base of the nozzle. The headlamp washer nozzle cannot be adjusted or repaired and, if ineffective or damaged, the entire nozzle and mounting bezel must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Spray Nozzle > Component Information > Description and Operation > Headlamp Washer Nozzle - Description > Page 10081 Headlamp Washer Spray Nozzle: Description and Operation Headlamp Washer Nozzle - Operation HEADLAMP When the headlamp washer pump/motor unit is activated, pressure builds within the high pressure hoses to each headlamp washer nozzle. Driven by this pressure, a control valve integral to each nozzle allows a precisely metered quantity of washer fluid to be sprayed in several high pressure streams against the lenses of both front lamp units. When the pressure drops, the control valve closes and the nozzle spray ceases. The headlamp washer system only operates when the engine is running and the headlamps are turned ON. When those conditions have been met, the headlamp washer system operates whenever the front (windshield) washer system is activated. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Spray Nozzle > Component Information > Service and Repair > Headlamp Washer Nozzle - Removal Headlamp Washer Spray Nozzle: Service and Repair Headlamp Washer Nozzle - Removal HEADLAMP CAUTION: Take proper precautions to ensure there is no cosmetic damage done to the paint finish of the headlamp washer nozzle bezel or the front fascia during the following procedure. 1. Raise and support the vehicle. 2. Remove the push pin retainers that secure the lower front edge of the front wheel house splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 3. Reach up behind the front fascia to access and securely clamp the headlamp washer supply hose to prevent the contents of the washer reservoir from draining during the following procedure. 4. From behind the front fascia, depress the two integral latches (1) of the washer nozzle bezel and push the nozzle out through the face of the fascia. 5. From the face of the front fascia, pull the nozzle out from the mounting hole far enough to access the headlamp washer nozzle supply hose (1) quick connect fitting (4). 6. Pull the molded plastic lock (2) away from the quick connect fitting far enough to disengage the hose from the washer nozzle nipple (3). 7. Remove the nozzle from the front fascia. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Spray Nozzle > Component Information > Service and Repair > Headlamp Washer Nozzle - Removal > Page 10084 Headlamp Washer Spray Nozzle: Service and Repair Headlamp Washer Nozzle - Installation HEADLAMP CAUTION: Take proper precautions to ensure there is no cosmetic damage done to the paint finish of the headlamp washer nozzle bezel or the front fascia during the following procedure. 1. Pull the washer nozzle supply hose (1) quick connect fitting (4) out through the mounting hole of the front fascia far enough to seat the molded plastic lock (2) onto the fitting. 2. Push the quick connect fitting onto the headlamp washer nozzle nipple (3) until it snaps into place with an audible click. 3. Position the headlamp washer nozzle into the mounting hole in the front fascia. 4. Align the washer nozzle bezel with the mounting hole in the front fascia. 5. Using hand pressure, push the bezel down into the fascia mounting hole until both bezel latch features are fully engaged on the back side of the fascia. 6. Reach up behind the front fascia to access and remove the clamp from the washer supply hose. 7. Reinstall the push pin retainers that secure the lower front edge of the front wheel house splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Description and Operation > Headlamp Washer Relay - Description Headlamp Washer Motor Relay: Description and Operation Headlamp Washer Relay - Description DESCRIPTION The headlamp washer relay (1) is a conventional International Standards Organization (ISO) skirted relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns (2), and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The headlamp washer relay is located in a dedicated connector on a take out of the Front End Module (FEM) wire harness, and is secured to the radiator closure panel to the left of the washer reservoir in front of the Totally Integrated Power Module (TIPM) in the engine compartment, near the battery. The headlamp washer relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Description and Operation > Headlamp Washer Relay - Description > Page 10090 Headlamp Washer Motor Relay: Description and Operation Headlamp Washer Relay - Operation OPERATION The headlamp washer relay is an electromechanical switch that uses a low current input from the Totally Integrated Power Module (TIPM) to control a high current output to the headlamp washer pump/motor unit. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The headlamp washer relay terminals are connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The inputs and outputs of the headlamp washer relay include: - Common Feed Terminal - The common feed terminal (30) is connected to battery current on a fused B(+) circuit from a fuse in the Totally Integrated Power Module (TIPM) at all times. Coil Ground Terminal - The coil ground terminal (85) is connected to battery current on a fused run relay output circuit from a fuse in the TIPM at all times. This circuit is energized by the run relay only while the engine is running. - Coil Battery Terminal - The coil battery terminal (86) is connected to a low side driver output from the TIPM on a headlamp washer relay control circuit. The TIPM controls headlamp washer system operation through this relay connection. - Normally Open Terminal - The normally open terminal (87) is connected through a headlamp washer relay output circuit to the headlamp washer pump/motor unit at all times. When the relay is energized, the normally open terminal of the relay is connected to battery current from the fuse in the TIPM. - Normally Closed Terminal - The normally closed terminal (87A) is not connected to any circuit in this application, but will have battery current present whenever the headlamp washer relay coil is not energized. The headlamp washer relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or the communication between modules and other devices that provide some features of the headlamp washer system. The most reliable, efficient, and accurate means to diagnose the headlamp washer relay or the electronic controls and communication related to headlamp washer system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10095 Washer Fluid Level Switch: Diagrams Connector - (FRONT END MODULE) 2 WAY SENSOR-WASHER FLUID LEVEL-FRONT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir on the upper left corner of the cooling module on the Front End Module (FEM). Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the FEM wire harness. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description > Page 10098 Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON request message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level indicator or the electronic controls or communication between other modules and devices that provide some features of the washer system. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the washer reservoir from the back of the cooling module on the Front End Module (FEM). See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Removal. 3. Disconnect the FEM wire harness connector from the washer fluid level switch connector receptacle (3) on the back of the reservoir. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir. Care must be taken not to damage the reservoir. 5. Remove the switch from the washer reservoir. 6. Remove the rubber grommet seal from the switch mounting hole in the washer reservoir and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal > Page 10101 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Installation INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented upward. 4. Reconnect the Front End Module (FEM) wire harness connector (3) to the switch connector receptacle. 5. Reinstall the washer reservoir onto the back of the cooling module on the FEM. See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Connector - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-RIGHT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Connector - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-RIGHT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description Wiper Switch: Description and Operation Right Multifunction Switch - Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. - Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 10110 - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides one momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 10111 Wiper Switch: Description and Operation Right Multifunction Switch - Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional analog switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard-wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10112 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See: Service and Repair/Right Multifunction Switch - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10113 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal Wiper Switch: Service and Repair Right Multifunction Switch - Removal REMOVAL WARNING: To avoid personal or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). 6. Remove the switch from the clockspring (3). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal > Page 10116 Wiper Switch: Service and Repair Right Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). Tighten the screw to 1 Nm (10 in. lbs.). 4. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 5. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10120 Washer Fluid Level Switch: Diagrams Connector - (FRONT END MODULE) 2 WAY SENSOR-WASHER FLUID LEVEL-FRONT - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir on the upper left corner of the cooling module on the Front End Module (FEM). Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the FEM wire harness. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description > Page 10123 Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON request message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level indicator or the electronic controls or communication between other modules and devices that provide some features of the washer system. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the washer reservoir from the back of the cooling module on the Front End Module (FEM). See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Removal. 3. Disconnect the FEM wire harness connector from the washer fluid level switch connector receptacle (3) on the back of the reservoir. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir. Care must be taken not to damage the reservoir. 5. Remove the switch from the washer reservoir. 6. Remove the rubber grommet seal from the switch mounting hole in the washer reservoir and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal > Page 10126 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Installation INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented upward. 4. Reconnect the Front End Module (FEM) wire harness connector (3) to the switch connector receptacle. 5. Reinstall the washer reservoir onto the back of the cooling module on the FEM. See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Installation. 6. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description Windshield Washer Hose: Description and Operation Front Washer Hoses and Tubes - Description FRONT The front washer plumbing consists of a small diameter rubber hose (2) that is routed along the left front fender ledge (4) from the washer reservoir hose (5) located at the left front corner of the engine compartment. The reservoir hose is attached to the front outlet nipple of the washer pump/motor unit near the bottom of the reservoir. The hose is then secured by plastic push-in type retainers to the left fender ledge within the engine compartment to the left side of the cowl plenum. From the cowl plenum, the front hose is routed up toward the inner hood panel reinforcement (1). The hose is secured to the left hood hinge and the left side of the inner hood panel reinforcement by plastic push-in type retainers, then is routed through the rear hood silencer brackets across the underside of the inner hood panel. Plastic in-line fittings, a molded rubber tee and a molded rubber elbow provide the take outs for the two front washer nozzles. Washer hose is available for service as roll stock, which may be cut to length. The molded plastic or rubber washer hose fittings cannot be repaired. If these fittings are ineffective or damaged, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10131 Windshield Washer Hose: Description and Operation Rear Washer Hoses and Tubes - Description REAR The rear washer plumbing consists of a small diameter rubber hose (3) that is routed along the left front fender shield (6) from the washer reservoir hose (5) located at the left front corner of the engine compartment. The reservoir hose is attached to the rear outlet nipple of the washer pump/motor unit near the bottom of the reservoir. The hose is then secured by a plastic clip retainer to the front end sheet metal within the engine compartment and routed to just behind the left strut tower, where it connects to the unibody hose (7). The unibody hose (1) passes from the engine compartment through a hole with a rubber grommet in the dash panel into the passenger compartment where it enters the body wire harness. The hose and wire harness bundle is routed along the floor panel (3) near the left sill back to the base of the left rear inner wheel house (2). The hose and wiring bundle is then routed over the wheel house and along the quarter inner panel near the belt line, then up the D-pillar. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10132 The unibody hose (3) exits the body wire harness near the top of the D-pillar, where it is connected to the liftgate washer hose (2) by a quick connect fitting. The liftgate washer hose is routed up the D-pillar to the upper liftgate opening header panel, then to the center of the upper liftgate opening. The liftgate hose is routed through a hole with a rubber grommet in the upper liftgate opening header panel and passes through another hole with a rubber grommet in the upper liftgate panel (1) to the rear washer nozzle on the upper liftgate. Washer hose is available for service as roll stock, which may be cut to length. The unibody washer hose is integral to the body wire harness. The molded plastic washer hose fittings and routing clips cannot be repaired. If these fittings or clips are ineffective or damaged, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10133 Windshield Washer Hose: Description and Operation Front Washer Hoses and Tubes - Operation FRONT Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the front washer system plumbing and fittings to the two front washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10134 Windshield Washer Hose: Description and Operation Rear Washer Hoses and Tubes - Operation REAR Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the rear washer system plumbing and fittings to the rear washer nozzle. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10138 Windshield Washer Pump: Diagrams Connector - (FRONT END MODULE) 2 WAY PUMP-WASHER-WINDSHIELD - (FRONT END MODULE) 2 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Front and Rear Windshield Washer Pump - Description Windshield Washer Pump: Description and Operation Front and Rear Windshield Washer Pump Description FRONT AND REAR The washer pump/motor unit is located on the top of a sump area on the rearward facing side of the washer reservoir, which is located on the upper left corner of the cooling module in the engine compartment. A small permanently lubricated and sealed reversible electric motor (3) is coupled to the rotor-type washer pump (4). The use of an integral valve body (7) allows the washer pump/motor unit to provide washer fluid to either the front or the rear washer systems, depending upon the direction of the motor/pump impeller rotation. An inlet nipple (6) on the pump housing passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir sump. The filter screen prevents most debris from entering the pump housing. When the pump is installed in the reservoir the front barbed outlet nipple (5) on the pump valve body housing connects the unit to the front washer hose, and the rear barbed outlet nipple (8) connects the unit to the rear washer hose. The letters F and R molded into the valve body housing adjacent to each nipple provide further clarification of the nipple assignments. The washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap fit between the motor housing and a receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (1) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the Front End Module (FEM) wire harness. Service replacement washer pumps may also include a snap post (2) at the top of the pump motor housing, but this feature is not used in this application. The washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire washer pump/motor unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Front and Rear Windshield Washer Pump - Description > Page 10141 Windshield Washer Pump: Description and Operation Front and Rear Windshield Washer Pump Operation FRONT AND REAR The washer pump/motor unit features a reversible electric motor. The direction of the motor is controlled by hard wired outputs from the Totally Integrated Power Module (TIPM). When battery current and ground are applied to the two pump motor terminals, the motor rotates in one direction. When the polarity of these connections is reversed, the motor rotates in the opposite direction. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through one of the two pump outlet nipples, and into the front or rear washer plumbing. The TIPM controls the hard wired outputs to the pump motor based upon electronic washer request messages received over the Controller Area Network (CAN) data bus from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC receives electronic washer switch status messages over a Local Interface Network (LIN) bus connection from the Steering Control Module (SCM) within the left (lighting) multi-function switch housing. The SCM monitors hard wired analog and multiplex inputs from the washer switch circuitry contained within the right (wiper) multi-function switch to determine the proper electronic messages to send. Washer fluid is drawn through the pump inlet nipple from the washer reservoir to the inlet port of the washer pump housing. An integral valve body is located in a housing on the outlet port side (2) of the pump housing. A diaphragm (4) in this valve body controls which washer system plumbing receives the washer fluid being pressurized by the pump. When the pump impeller (1) rotates in the counterclockwise direction (viewed from the bottom), the biased diaphragm is sealing off the rear washer system outlet and nipple so the pressurized washer fluid is pushed out through the pump front outlet port and the front washer outlet nipple (5). When the pump impeller rotates in the clockwise direction (viewed from the bottom), pressurized washer fluid is pushed out through the pump rear outlet port and moves the diaphragm to open the rear washer outlet nipple and seal off the front washer outlet nipple, then the pressurized washer fluid is pushed out through the rear washer outlet nipple (3). The washer pump/motor unit and the hard wired motor control circuits from the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer pump/motor unit or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit or the electronic controls and communication related to washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front and Rear Windshield Washer Pump - Removal Windshield Washer Pump: Service and Repair Front and Rear Windshield Washer Pump Removal FRONT AND REAR 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir into a clean container for reuse. 3. Remove the washer reservoir from the cooling module. See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir Removal. 4. Pull lightly outward on the top of the washer pump/motor housing (2), away from the washer reservoir to disengage the top of the motor from the receptacle in the reservoir. 5. Using hand pressure, firmly grasp and pull the washer pump upward far enough to disengage the pump inlet nipple from the rubber grommet seal/filter screen in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the washer pump/motor unit from the washer reservoir. 7. Remove the rubber grommet seal/filter screen from the washer pump mounting hole in the reservoir and discard. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front and Rear Windshield Washer Pump - Removal > Page 10144 Windshield Washer Pump: Service and Repair Front and Rear Windshield Washer Pump Installation FRONT AND REAR 1. Install a new rubber grommet seal/filter screen into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal/filter screen on the reservoir. 2. Position the inlet nipple on the base of the pump housing of the washer pump/motor unit (2) to the rubber grommet seal/filter screen in the reservoir. 3. Using hand pressure, press firmly and evenly downward on the top of washer pump/motor unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump mounting hole of the reservoir. 4. Align the top of the washer pump/motor unit housing with the receptacle in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the motor housing snaps into the receptacle. 6. Reinstall the washer reservoir onto the cooling module. See: Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir Installation. 7. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 8. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Windshield Washer Reservoir - Description Windshield Washer Reservoir: Description and Operation Windshield Washer Reservoir Description DESCRIPTION The molded plastic washer fluid reservoir (1) is mounted on the upper left corner of the cooling module on the back of the Front End Module (FEM) carrier (also known as the radiator closure). The filler neck for the reservoir extends upward just past the upper radiator closure member and through the upper radiator seal. This reservoir is constructed of opaque black plastic, which does not allow the fluid level to be inspected without removing the reservoir filler cap (2). The bright yellow plastic filler cap with a rubber seal and an International Control and Display Symbol icon for Windshield Washer molded into it snaps over the open end of the washer reservoir filler neck. The cap hinges on and is secured to an integral molded hook formation on the top of the reservoir just to the left of the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. The washer reservoir is secured to the cooling module through integral mounting brackets at the top on the inboard and outboard sides by two screws. In addition, integral mounting tab provisions on the bottom of the washer reservoir engage through slots or slotted loops integral to the cooling module to secure the lower end of the reservoir. There is a dedicated mounting hole in the top of the sump area on the rearward facing side of the reservoir with a receptacle provided for the mounting of the reversible washer/pump motor unit (3) without the use of fasteners. A separate dedicated mounting hole is provided in the rearward facing side of the reservoir for the washer fluid level switch (4). An integral molded routing trough for the washer hose and washer pump/motor unit wiring routes the hose and wiring bundle from the washer pump to the outboard side of the reservoir. A unique reservoir is used for vehicles manufactured for export markets with the optional headlamp washer system. This reservoir has a dedicated sump area and mounting receptacle for the high pressure headlamp washer pump (5) near the outboard side of the reservoir, directly above the washer fluid level switch location. The location and mounting provisions for this reservoir are the same as for those vehicles without the headlamp washer system. A washer reservoir cannot be repaired and, if ineffective or damaged, the unit must be replaced. The reversible washer pump/motor unit, the washer fluid level switch, the headlamp washer pump/motor unit, their rubber grommet seals, as well as the reservoir filler cap are each available for individual service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Windshield Washer Reservoir - Description > Page 10149 Windshield Washer Reservoir: Description and Operation Windshield Washer Reservoir Operation OPERATION The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the front, rear and, if equipped, headlamp washer systems. The washer reservoir filler cap provides a clearly marked and readily accessible point at which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted far enough above the washer pump inlet nipple in the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer system will no longer operate. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Reservoir - Removal Windshield Washer Reservoir: Service and Repair Windshield Washer Reservoir - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir into a clean container for reuse. 3. If equipped with certain optional engines, it may be necessary to remove the air filter housing for access to the washer reservoir mounting provisions and connections. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 4. If the vehicle is so equipped, disconnect the Front End Module (FEM) wire harness connector (2) and headlamp washer supply hose (1) from the headlamp washer pump/motor unit (3). To disconnect the quick connect fitting (4), pull the molded plastic lock (2) away from the headlamp washer supply hose quick connect fitting far enough to disengage the hose from the washer pump nipple. 5. Disconnect the FEM wire harness connector (5) from the washer fluid level switch connector receptacle on the back of the reservoir. 6. Disconnect the FEM wire harness connector (3) and the front and rear washer supply hoses (4) from the reversible washer pump/motor unit. 7. Disengage each of the FEM wire harness takeouts and washer supply hoses from the integral routing provisions of the washer reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Reservoir - Removal > Page 10152 8. Remove the two screws (1) that secure the washer reservoir inboard and outboard mounting brackets to the back of the cooling module. 9. Lift the washer reservoir straight up to disengage the mounting tabs from the cooling module. 10. Remove the washer reservoir from the left side of the cooling module. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Reservoir - Removal > Page 10153 Windshield Washer Reservoir: Service and Repair Windshield Washer Reservoir - Installation INSTALLATION 1. Position the washer reservoir to the left side of the cooling module. 2. Engage the mounting provisions at the bottom of the washer reservoir with the cooling module. 3. Install and tighten the two screws (1) that secure the washer reservoir inboard and outboard mounting brackets to the back of the cooling module. Tighten the screws securely. 4. Engage each of the Front End Module (FEM) wire harness takeouts and washer supply hoses into the integral routing provisions of the washer reservoir. 5. Reconnect the FEM wire harness connector (3) and the front and rear washer supply hoses (4) to the reversible washer pump/motor unit. 6. Reconnect the FEM wire harness connector (5) to the washer fluid level switch connector receptacle on the back of the reservoir. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Reservoir - Removal > Page 10154 7. If the vehicle is so equipped, reconnect the FEM wire harness connector and headlamp washer supply hose (1) to the headlamp washer pump /motor unit. To reconnect the quick connect fitting (4), first seat the molded plastic lock (2) onto the washer supply hose quick connect fitting. Next, push the quick connect fitting onto the headlamp washer pump/motor unit outlet nipple (3) until it snaps into place with an audible click. 8. If removed, reinstall the air filter housing. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. 9. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 10. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description Windshield Washer Spray Nozzle: Description and Operation Washer Nozzle - Description REAR The fluidic rear washer nozzle is constructed of molded plastic and includes an integral check valve. The rear washer nozzle is secured by two integral latch features (3) within a mounting hole to the left of the Center High-Mounted Stop Lamp (CHMSL) in the lower surface of the brow above the liftgate glass opening in the outer liftgate panel. The outer surface of the washer nozzle is visible on the lower exterior surface of the liftgate, and a rubber gasket (1) seals the nozzle to the spoiler mounting hole. The nozzle orifice (2) is oriented downward towards the liftgate glass. The washer plumbing fitting (4) is concealed between the liftgate inner and outer panels. The rear washer nozzle cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description > Page 10159 Windshield Washer Spray Nozzle: Description and Operation Washer Nozzle - Operation REAR The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the washer pump/motor through a single hose, which is attached to a barbed nipple on the back of the nozzle. A fluidic matrix within the nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve in the nozzle prevents washer fluid from draining out of the washer supply hose back to the washer reservoir. This drain-back would result in a lengthy delay after the washer switch is actuated until washer fluid was dispensed through the nozzle because the washer pump would have to refill the washer plumbing from the reservoir to the nozzle. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzle after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer plumbing is prevented. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description > Page 10160 Windshield Washer Spray Nozzle: Description and Operation Front Washer Nozzle - Description FRONT The fluidic front washer nozzles (2) are constructed of molded plastic and include an integral check valve. Each nozzle has two integral latches (3) that secure them in dedicated holes in the hood panel near the base of the windshield. The domed upper surface of the washer nozzle is visible on the outside of the hood panel, and the two nozzle orifices (1) are oriented towards the windshield glass. An integral diaphragm type check valve is contained within the body of each nozzle. The washer plumbing fittings (4) for the washer nozzles extend below the hood panel and are accessible from the engine compartment. The front washer nozzles cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description > Page 10161 Windshield Washer Spray Nozzle: Description and Operation Front Washer Nozzle - Operation FRONT The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the inner hood panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve in each nozzle prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay after the washer switch is actuated until washer fluid was dispensed through the nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer plumbing is prevented. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle - Removal Front FRONT 1. From the underside of the hood (3), remove the push-in retainers that secure the rear edge of the hood silencer pad to the inner hood reinforcement as necessary to access the washer nozzle hose (2) connections. 2. From the underside of the hood, disconnect the washer nozzle hose from the barbed nipple (1) of the washer nozzle. 3. From the underside of the hood, release the integral latch features of the washer nozzle (1) and push the nozzle out through the mounting hole toward the top side of the hood. 4. Remove the washer nozzle from the top of the hood panel. Rear REAR NOTE: The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. If removed from its mounting hole for any reason, the rear washer nozzle must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 10164 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry the rear washer nozzle (3) to release the latch features that secure it in the mounting hole of the liftgate outer panel (1). 2. Pull the rear washer nozzle out from the liftgate outer panel far enough to access the washer supply hose (2). 3. Disconnect the hose from the barbed nipple on the back of the nozzle. 4. Cut 4 to 6 millimeters (0.15 to 0.23 inch) from the end of the hose to ensure a good fit to the barbed nipple of the replacement rear washer nozzle. 5. Discard the removed nozzle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 10165 Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle - Installation Front FRONT 1. From the top of the hood, position the washer nozzle (1) to the mounting hole on the outside of the hood panel (2). 2. Align the anti-rotation tabs of the nozzle with the anti-rotation notches in the mounting hole. 3. Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral latch features lock into place on the underside of the hood. 4. From the underside of the hood (3), reconnect the washer hose (2) fitting to the barbed nipple (1) of the washer nozzle. 5. Reinstall the washer nozzle hose into its routing clips as necessary on the underside of the hood. 6. Reinstall the push-in retainers that secure the rear edge of the hood silencer pad to the inner hood reinforcement. Rear REAR NOTE: The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. If removed from its mounting hole for any reason, the rear washer nozzle must be replaced with a new unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 10166 1. Position the new rear washer nozzle (3) to the mounting hole in the liftgate outer panel (1). Be certain that the rubber gasket is in position on the back of the nozzle. 2. Reconnect the washer supply hose (2) to the barbed nipple on the back of the nozzle. 3. Push the hose and nozzle nipple into the mounting hole in the liftgate outer panel and align the anti-rotation tab to the mounting hole. 4. Using hand pressure, push firmly and evenly on the nozzle until both integral latch features are fully engaged on the back side of the outer panel. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Connector - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-RIGHT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Wiper Arm - Description Wiper Arm: Description and Operation Wiper Arm - Description Front FRONT The front wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arm has a die cast metal pivot end (4) with a large tapered mounting hole (5) at one end. A molded black plastic cap fits over the wiper arm retaining nut to conceal the nut and this mounting hole following wiper arm installation. The wide end of a tapered, stamped steel channel (3) hinges on and is secured with a hinge pin (6) to the blade end of the wiper arm pivot end. One end of a long, rigid, stamped steel strap (2) with a small hole near its pivot end is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook (1). Concealed within the stamped steel channel, one end of a long tension spring is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. The right and left wiper arms are unique and are not interchangeable. A wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. Rear REAR The rear wiper arm is the rigid member located between the rear wiper motor output shaft that protrudes through the liftgate outer panel below the center Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Wiper Arm - Description > Page 10174 of the liftgate glass opening and the wiper blade on the outside of the glass. The wiper arm is constructed of molded black plastic. A hinged pivot end is also molded plastic. A molded black plastic nut cover (2) with two pivot pins on one end and a snap feature on the other fits over the wiper arm retaining nut to conceal the nut and mounting hole following wiper arm installation. The wiper arm hinge and tension spring are concealed on the underside of the wide end of the arm (1), while an integral latch feature (3) concealed on the underside of the narrow end of the wiper arm accepts the pivot pin of the matching molded plastic wiper blade unit. The rear wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Wiper Arm - Description > Page 10175 Wiper Arm: Description and Operation Wiper Arm - Operation Front FRONT The front wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The tapered mounting hole in the wiper arm pivot end interlocks with the serrations on the tapered outer circumference of the wiper pivot shaft, allowing positive engagement and finite adjustment of this connection. The mounting nuts lock the wiper arms to the threaded studs of the wiper pivot shafts. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Rear REAR The rear wiper arm is designed to mechanically transmit the motion from the rear wiper motor output shaft to the rear wiper blade. The wiper arm must be properly indexed to the motor output shaft in order to maintain the proper wiper blade travel on the glass. The tapered hole in the wiper arm pivot end interlocks with the serrations on the outer circumference of the tapered motor output shaft, allowing positive engagement and finite adjustment of this connection. A hex nut secures the wiper arm pivot end to the threads on the rear wiper motor output shaft and the plastic cover snaps over this connection for a neat appearance. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The latch formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot pin to the wiper arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal Wiper Arm: Service and Repair Wiper Arm - Removal Front FRONT 1. Lift the front wiper arm (1) to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to pivot shaft connection. 2. Carefully pry the plastic nut cap (2) off of the pivot end of the wiper arm. 3. Remove the nut (3) that secures the wiper arm to the wiper pivot shaft. 4. If necessary, use a suitable battery terminal puller (3) to disengage the wiper arm (1) from the pivot shaft (2). 5. Remove the front wiper arm pivot end from the pivot shaft. Rear REAR Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 10178 1. Unsnap and swing the molded plastic nut cover (2) off of the pivot end of the wiper arm (1). 2. Remove the nut (4) that secures the wiper arm to the rear wiper motor output shaft (3). CAUTION: The use of a battery terminal puller when removing the rear wiper arm is NOT recommended as this may damage the rear wiper arm. 3. Use a slight rocking action to disengage the rear wiper arm pivot end from the output shaft and remove the wiper arm. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 10179 Wiper Arm: Service and Repair Wiper Arm - Installation Front Wiper Arm FRONT NOTE: Be certain that the wiper motor is in the park position before attempting to install the front wiper arms. Turn the ignition switch to the ON position and move the right (wiper) multi-function switch control knob to its OFF position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the OFF position. The front wiper motor is now in its park position. 1. The front wiper arms (1) must be indexed to the pivot shafts with the front wiper motor in the park position to be properly installed. Position the wiper arm pivot ends onto the wiper pivot shafts so that the tip of the wiper blade is aligned with the wiper alignment lines located within the lower margin (blackout area) of the windshield glass. 2. Once the wiper blade is aligned, lift the wiper arm away from the windshield slightly to relieve the spring tension on the pivot end and push the pivot end of the wiper arm down firmly and evenly over the pivot shaft. 3. Install and tighten the nut (3) that secures the wiper arm to the pivot shaft. Tighten the nut to 24 Nm (18 ft. lbs.). 4. Wet the windshield glass, then operate the front wipers. Turn the front wipers OFF, then check for the correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap (2) onto the wiper arm pivot nut. Wiper Arm INSTALLATION NOTE: Be certain that the rear wiper motor is in the park position before attempting to install the rear wiper arm. Turn the ignition switch to the ON position and move the rear wiper switch to its OFF position. If the wiper motor output shaft moves, wait until it stops moving, then turn the ignition switch back to the OFF position. The wiper motor is now in its park position. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 10180 1. The rear wiper arm (1) must be indexed to the rear wiper motor output shaft with the motor in the park position to be properly installed. Position the wiper arm pivot end onto the output shaft (3) so that the tip of the wiper blade is aligned with the second rear window defogger grid line from the bottom of the liftgate glass. 2. With the rear wiper arm properly indexed, push the tapered mounting hole on the pivot end of the wiper arm down over the output shaft. 3. Install and tighten the nut (4) that secures the rear wiper arm to the output shaft. Tighten the nut to 9 Nm (80 in. lbs.). 4. Fold and snap the molded plastic nut cover (2) over the nut on the pivot end of the rear wiper arm. 5. Wet the lift glass and operate the rear wiper. Turn the rear wiper switch to the OFF position, then check for correct wiper arm position and readjust as required. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Wiper Blade - Description Wiper Blade: Description and Operation Wiper Blade - Description Front FRONT Each wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations (6) that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure. The passenger side wiper blades are 47.50 centimeters (18.70 inches) long. The driver side wiper blades are 60 centimeters (23.62 inches) long. They have non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. Rear REAR The rear wiper blade is secured by an integral pivot pin (2) to a receptacle at the tip of the rear wiper arm, and rests near the base of the liftgate glass when the wiper is not in operation. The rear wiper blade consists of the following components: Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Wiper Blade - Description > Page 10185 - Superstructure (1) - The superstructure includes a molded black plastic bridge and plastic links with claw formations that grip the wiper blade element. Also included in this unit is the pivot pin that secures the superstructure to the wiper arm. - Element (3) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure. The rear wiper blade is 30.50 centimeters (12.00 inches) long with a non-replaceable element (squeegee). The wiper blade superstructure cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Wiper Blade - Description > Page 10186 Wiper Blade: Description and Operation Wiper Blade - Operation Front FRONT The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Rear REAR The rear wiper blade is moved back and forth across the liftgate glass by the wiper arm when the rear wiper system is in operation. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature found across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Removal Wiper Blade: Service and Repair Wiper Blade - Removal Front FRONT CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. Rear REAR 1. Lift the rear wiper arm pivot cap (2) upward to allow the rear wiper blade to be raised off of the glass. NOTE: The rear wiper arm cannot be raised to its over-center hinge position unless the pivot cover is raised first. 2. Lift the rear wiper arm to its over-center hinge position to raise the wiper blade and element off of the liftgate glass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Removal > Page 10189 3. To remove the wiper blade (1) from the wiper arm (3), grasp the end of the blade nearest to the motor output shaft, then over-rotate it out from under the arm and past its stop far enough to unsnap the blade pivot pin (2) from the receptacle (4) on the end of the arm. 4. Gently lower the tip of the wiper arm onto the glass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Removal > Page 10190 Wiper Blade: Service and Repair Wiper Blade - Installation Front FRONT CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Rear REAR 1. Lift the rear wiper arm pivot cap (2) upward to allow the rear wiper arm to be raised off of the glass. NOTE: The rear wiper arm cannot be raised to its over-center hinge position unless the pivot cover is raised first. 2. Lift the rear wiper arm to its over-center hinge position and off of the liftgate glass. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Removal > Page 10191 3. Position the rear wiper blade (1) with the pivot pin (2) aligned with the opening of the receptacle (4) on the tip of the wiper arm (3). 4. Using hand pressure, press the wiper blade pivot pin firmly and evenly into the wiper arm receptacle until it snaps into place. 5. Lower the wiper blade onto the glass and snap the pivot cover back into place. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Front Wiper Motor Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Front Wiper Motor > Page 10196 Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor (Liftgate) 4 Way Wiper Motor: Diagrams Rear Wiper Motor (Liftgate) 4 Way Connector - (LIFTGATE) 4 WAY MOTOR-WIPER-REAR - (LIFTGATE) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor (Liftgate) 4 Way > Page 10199 Wiper Motor: Diagrams Front Wiper Motor (Headlamp And Dash) 4 Way Connector - (HEADLAMP AND DASH) 4 WAY MOTOR-WIPER-FRONT - (HEADLAMP AND DASH) 4 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Wiper Motor - Description Wiper Motor: Description and Operation Wiper Motor - Description REAR The rear wiper motor is concealed within the liftgate, below the liftgate glass and behind the liftgate inner trim panel. The end of the motor output shaft (1) that extends through the liftgate outer panel to drive the rear wiper arm and blade is the only visible component of the rear wiper motor. A rubber bezel and grommet is engaged within the output shaft hole of the liftgate outer panel and seals the output shaft where it passes through the panel. An integral connector receptacle (4) connects the rear wiper motor to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. The rear wiper motor consists of the following major components: - Bracket (5) - The rear wiper motor bracket consists of a stamped metal mounting plate for the wiper motor that is secured with screws to the wiper motor transmission housing, and through three rubber isolators (2) to the liftgate inner panel. - Motor (3) - The single-speed permanent magnet rear wiper motor is secured with screws to the rear wiper motor transmission, which is secured to the motor bracket with screws. The wiper motor includes the integral transmission, the motor output shaft, an automatic resetting circuit breaker, and the rear wiper motor park switch that parks the rear wiper blade near the base of the liftgate glass. The rear wiper motor cannot be adjusted or repaired. If any component of the motor is ineffective or damaged, the entire rear wiper motor unit must be replaced. The output shaft bezel and grommet unit is available for individual service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Wiper Motor - Description > Page 10202 Wiper Motor: Description and Operation Wiper Motor - Operation REAR The rear wiper motor operation is controlled by the Totally Integrated Power Module (TIPM), which uses intelligent, high current, self-protected high side switches to control rear wiper system operation for energizing or de-energizing the rear wiper motor. The TIPM uses internal programming and electronic messages received over the Controller Area Network (CAN) data bus from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to provide the appropriate rear wiper and washer system operating modes. The EMIC uses electronic messages received from the Steering Control Module (SCM) over a Local Interconnect Network (LIN) data bus to determine when to send electronic rear wiper system requests to the TIPM. The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes and opens a path to ground for the rear wiper motor electronic control logic circuitry of the TIPM, depending upon the position of the rear wiper blade on the liftgate glass. This input allows the electronic logic circuits of the TIPM to control all of the electronic features of rear wiper motor operation and to keep the motor energized long enough to complete its current wipe cycle and park the wiper blade after the wiper system or the ignition switch has been turned OFF. The rear wiper motor is grounded at all times through a take out in the body wire harness that is secured to a remote ground location. The automatic resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade on the liftgate glass. The hard wired inputs and outputs of the rear wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the rear wiper system or the electronic controls and communication related to rear wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal Wiper Motor: Service and Repair Wiper Motor - Removal Front FRONT CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing a drive link from, or installing a drive link onto the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper linkage module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper motor and crank arm unit MUST be replaced. 1. Unlatch and open the hood. 2. Remove both front wiper arms from the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Disconnect and isolate the battery negative cable. 4. Remove the outer and inner cowl plenum cover/grille panels from the vehicle. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Removal and See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover - Removal. 5. Disconnect the headlamp and dash wire harness connector from the wiper motor pigtail wire connector (3). 6. Disengage the socket bushing (2) of the right wiper drive link from the ball stud on the wiper motor crank arm using two large screwdrivers, one on each side of the ball stud. Pry between the crank arm and the metal portion of the drive link until the socket unsnaps from the ball. 7. Disengage the sleeve bushing of the left wiper drive link from the ball stud on the wiper motor crank arm using two large screwdrivers, one on each side of the ball stud. Pry between the crank arm and the metal portion of the drive link until the sleeve unsnaps from the ball. 8. Remove the three screws (1) that secure the wiper motor to the center bracket (4) of the wiper linkage module. 9. Remove the wiper motor from under the wiper linkage module bracket and out of the cowl plenum. Rear REAR Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10205 1. Disconnect and isolate the battery negative cable. 2. Remove the rear wiper arm (3) from the rear wiper motor output shaft. See: Wiper Arm/Service and Repair/Wiper Arm - Removal. NOTE: The output shaft bezel and grommet (4) does not have to be removed to remove the rear wiper motor from the liftgate. 3. Remove the trim panel from the liftgate inner panel (2). See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 4. Disconnect the wire harness connector (7) from the rear wiper motor (1). 5. Remove the three screws (6) that secure the motor mounting bracket to the liftgate inner panel. 6. Remove the motor from the liftgate. 7. Remove the bezel and rubber grommet on the outer liftgate panel from the output shaft clearance hole. Be certain to take proper precautions to protect the outer liftgate panel and its paint finish from damage during this procedure. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10206 Wiper Motor: Service and Repair Wiper Motor - Installation Front FRONT CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing a drive link from, or installing a drive link onto the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper linkage module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper motor and crank arm unit MUST be replaced. 1. Position the front wiper motor to the center bracket (4) of the wiper linkage module from the underside of the bracket. 2. Install and tighten the three screws (1) that secure the motor to the bracket. Tighten the screws to 9 Nm (80 in. lbs.). 3. Reconnect the headlamp and dash wire harness connector to the wiper motor pigtail wire connector (3). Be certain to route the wire harness take out under the wiper linkage module. 4. Reconnect the battery negative cable. 5. Turn the ignition switch (also known as the Wireless Ignition Node/WIN) to the ON position. WARNING: To avoid serious or fatal injury and vehicle damage, be certain there are no objects including hands or fingers in the rotational path of the wiper motor crank arm. The following step will activate the front wiper motor to ensure it is in the Park position, and may cause the motor crank arm to complete up to one complete revolution. 6. Turn the front wiper system ON, then back to OFF using the right (wiper) multi-function switch control knob. 7. Wait until the wiper motor stops moving, then turn the ignition switch back to the OFF position. 8. Position the sleeve bushing of the left wiper drive link onto the ball stud on the end of the motor crank arm. Place a short 19 millimeter or 3/4 inch socket over the bushing as an installation tool. Then use large channel-lock pliers to apply enough pressure to the underside of the crank arm and the top of the socket to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushing. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10207 CAUTION: Carefully inspect the installed sleeve bushing (2) to be certain it is centered over the lower ball of the ball stud (3), and not trapped between the lower ball and the crank arm (1). There should be a visible clearance between the lower surface of the sleeve bushing and the crank arm. Refer to the accompanying illustration. The sleeve bushing must be able to swivel freely on the lower ball during wiper operation. If the bushing is trapped between the lower ball and the crank arm, the bushing and the drive link (4) may be damaged. 9. Position the socket bushing of the right wiper drive link over the ball stud on the crank arm. Place a short 19 millimeter or 3/4 inch socket over the bushing as an installation tool. Then use large channel-lock pliers to apply enough pressure to the underside of the crank arm and the top of the socket to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushing. 10. Reinstall the inner and outer cowl plenum cover/grille panels. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover - Installation and See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Installation. 11. Reinstall both front wiper arms onto the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Installation. Rear REAR 1. If the output shaft bezel and grommet (4) were removed from the outside of the liftgate, install the rubber bezel and grommet into the clearance hole of the liftgate outer panel. Be certain the arrow (5) molded onto the grommet is oriented upward. 2. Position the rear wiper motor and bracket unit (1) onto the liftgate inner panel (2) as a unit. 3. Install and tighten the three screws (6) that secure the mounting bracket to the liftgate. Tighten the screws to 5 Nm (44 in. lbs.). 4. Reconnect the wire harness connector (7) to the motor connector receptacle. 5. Reinstall the trim panel onto the liftgate inner panel. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10208 Panel/Service and Repair/Liftgate Trim Panel - Installation. 6. Reinstall the rear wiper arm (3) onto the output shaft. See: Wiper Arm/Service and Repair/Wiper Arm - Installation. 7. Reconnect the battery negative cable. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Wiper Arm Linkage - Description Wiper Motor Linkage: Description and Operation Wiper Arm Linkage - Description DESCRIPTION The front wiper linkage module is secured by three screws through three rubber grommet-type insulators to two brackets and weld nuts on the cowl plenum panel and one bracket and weld nut on the driver side strut tower. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades and are the only visible components of the front wiper linkage module. The front wiper linkage module consists of the following major components: Bracket - The front wiper module bracket consists of a long tubular steel main member that has a die cast pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting bracket for the wiper motor is secured near the center of the main member. Each of the two wiper pivot brackets secures the module to the cowl plenum with a screw through a rubber insulator (4), and a third rubber insulator on the motor bracket secures the module with a screw in the bracket on the driver side strut tower. - Crank Arm - The front wiper motor crank arm (6) is a stamped steel unit with a hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a long ball stud secured to the drive end to accept the wiper linkage. - Linkage - Two stamped steel drive links (3) connect the wiper motor crank arm to the wiper pivot lever arms. The right side drive link has a plastic socket-type bushing on each end. The left side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm of its respective pivot. The left side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the right side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor - The front wiper motor (1) features a transmission housing from which the wiper motor output shaft exits, and has three mounting bosses with internal threads to which the motor is mounted to the center wiper linkage module bracket with screws. is secured with three screws near the center of the main tubular member of the wiper module bracket. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. A short pigtail wire and connector (5) connect the wiper motor to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. - Pivots - The two front wiper pivots (2) are secured within the die cast pivot brackets on the outboard ends of the wiper linkage module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a finely splined and tapered driver with a threaded stud extending from the top. The lower ends of the pivot shafts are installed through permanently lubricated bushings in the pivot brackets. The front wiper linkage module cannot be adjusted or repaired. The wiper motor is available for separate service replacement. If any other component of the linkage module is ineffective or damaged, the entire wiper linkage module unit must be replaced. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Wiper Arm Linkage - Description > Page 10213 Wiper Motor Linkage: Description and Operation Wiper Arm Linkage - Operation OPERATION The front wiper linkage module operation is controlled by the battery current inputs received by the wiper motor from the Totally Integrated Power Module (TIPM). The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. The hard wired inputs and outputs of the wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between other modules and devices that provide some features of the wiper system. The most reliable, efficient, and accurate means to diagnose the wiper system or the electronic controls and communication related to wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Wiper Arm Linkage - Removal Wiper Motor Linkage: Service and Repair Wiper Arm Linkage - Removal REMOVAL NOTE: The front wiper linkage module includes the wiper motor. The wiper motor is also available for separate service replacement and can be removed from the wiper linkage module without removing the module from the vehicle. See: Wiper Motor/Service and Repair/Wiper Motor - Removal . 1. Remove both front wiper arms from the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Removal. 2. Disconnect and isolate the battery negative cable. 3. Remove the outer and inner cowl plenum cover/grille panels from the vehicle. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Removal and See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover - Removal. 4. Disconnect the headlamp and dash wire harness connector (2) from the wiper motor pigtail wire connector. 5. Remove the three screws (1) that secure the front wiper linkage module (4) to the driver side strut tower bracket (3) and the two cowl brackets (5). 6. Remove the front wiper linkage module from the vehicle as a unit. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Wiper Arm Linkage - Removal > Page 10216 Wiper Motor Linkage: Service and Repair Wiper Arm Linkage - Installation INSTALLATION NOTE: The front wiper linkage module includes the wiper motor. The wiper motor is also available for separate service replacement and can be removed from the wiper linkage module without removing the module from the vehicle. See: Wiper Motor/Service and Repair/Wiper Motor - Removal . 1. Position the front wiper linkage module (4) into the vehicle as a unit. 2. Reconnect the headlamp and dash wire harness connector (2) to the wiper motor pigtail wire connector. Be certain to route the wire harness take out under the wiper linkage module. 3. Install but do not tighten the three screws (1) that secure the front wiper linkage module to the driver side strut tower bracket (3) and the two cowl brackets (5). 4. Starting on the driver side and working toward the passenger side, tighten each of the three screws. Tighten the screws to 10 Nm (90 in. lbs.). 5. Reinstall the inner and outer cowl plenum cover/grille panels. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Inner Cover - Installation and See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Outer Cover - Installation. 6. Reconnect the battery negative cable. 7. Reinstall both front wiper arms onto the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Installation. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Connector - (STEERING WHEEL JUMPER) 7 WAY SWITCH-MULTIFUNCTION-RIGHT - (STEERING WHEEL JUMPER) 7 WAY Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description Wiper Switch: Description and Operation Right Multifunction Switch - Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. - Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 10222 - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides one momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 10223 Wiper Switch: Description and Operation Right Multifunction Switch - Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional analog switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a failsafe mode of operation for the front and rear wiper systems. The failsafe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard-wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10224 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See: Service and Repair/Right Multifunction Switch - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10225 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Journey Awd Workshop Manual (V6-3.5L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal Wiper Switch: Service and Repair Right Multifunction Switch - Removal REMOVAL WARNING: To avoid personal or fatal injury, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tabs on the switch housing from the channel formations in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). 6. Remove the switch from the clockspring (3).